ASSAM POWER DISTRIBUTION COMPANY LIMITED BIDDING … · cutting of composite core wire. The...

ASSAM POWER DISTRIBUTION COMPANY LIMITED

BIDDING DOCUMENT(FULL TURNKEY CONTRACT)

FORDTR METERING WORKSIN ALL 27 DISTRICTS OF ASSAM

VOLUME-III(TECHNICAL SPECIFICATONS & DRAWINGS)

(UNDER DEENDAYAL UPADHYAYA GRAM JYOTI YOJANA)

Section-I : Technical SpecificationsSection-II : Tender Drawings

SPECIFICATION No.: APDCL/CGM (RE)/DDUGJY/DTR METERING

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VOLUME-III: SECTION – I

TECHNICAL SPECIFICATIONS

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Section-I

Technical Specification for Equipment’s

All materials required to complete the work as per given specifications & drawings etc. mustbe manufactured and supplied using fresh raw material. Re-moulded, re-circulated materialsare not acceptable. The procurement of materials must be made by the contractor directlyfrom manufacturer or through authorized dealer/distributors. Documentary evidences to thiseffect are to be made available to Employer for necessary checks/verification of source ofsupply of materials. Second hand materials/ partial used materials/ used materials would notacceptable.

Materials/equipments should also conform to the Guaranteed Technical Particulars (GTP)uploaded in this Bid Document or have to be approved before ordering the materials.

General practice of the employer for utilization/erection/rating of materials shall also beadopted, for example, the secondary coil of CT will be of 5 Amp, 110 Volt DC for ControlCircuit/ Battery, Differential Relay for protection of Transformer 5 MVA and above is practicedby APDCL. The secondary current rating of CT at EHT substations under AEGCL will be of 1Amp .The Technical Specification shall be modified accordingly.

The manufacturer of Power Transformer, Circuit Breaker, Control & Relay Panels and othermajor equipments will have to provide necessary spares on payment basis unconditionallyafter expiry of guarantee period, as and when required for maintenance of the equipments.Distribution Transformers should be manufactured by BIS certified manufacturer.

Climatic condition details are given with various materials specifications however, bidder shallnote that materials covered under project specific DDUGJY works shall be utilized in thatparticular project only. Hence, the geographical location of that particular project site and itsassociated climatic condition shall be applicable for all the materials of that particular project.

Marking of equipments/materials by project name ‘DDUGJY-II’, name of employer ‘APDCL’,Serial Number etc. as per REC instruction is a must in this project.

All items in this project should be made in India.

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Contents

1. ACSR Conductors................................................................................................................ 4

2. Mild Steel Channel, Angle And Flat ................................................................................... 22

3. 1.1 kV Grade Copper Stranded Control Cable ................................................................... 23

4. 11kV Porcelain Insulators and Fittings............................................................................. 26

5. 11 kV/22 kV/33 kV Composite Insulators ........................................................................ 40

6. 33 & 11 kV Station Class Lightning Arrestor & 11 kV Distribution Class Surge Arrestors 58

7. 11KV & 33 KV Metering Units ........................................................................................... 76

8. Energy Meter .................................................................................................................... 84

9. Earthing.......................................................................................................................... 119

10. Gi Earthing Pipe.............................................................................................................. 123

11. Clamps & Connectors ..................................................................................................... 125

12. Wiring ............................................................................................................................ 126

13. Equipment Erection Notes .............................................................................................. 127

14. Danger Notice Plates ...................................................................................................... 128

15. Number Plate (Support) ................................................................................................. 132

16. Cable Glands and Lugs ................................................................................................... 134

17. Cables Tags and Markers ................................................................................................ 135

18. GI Wires ........................................................................................................................ 138

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1. ACSR Conductors

A. ACSR CONDUCTOR

1. SCOPE

This section covers design, manufacture, testing before dispatch, packing, supply and delivery fordestination of Kms of “WEASEL” " RABBIT", "RACOON", "DOG", and "PANTHER" ACSR Conductor of size6/1/2.59mm, 6/1/3.35mm, 6/1/4.09 mm, 6/4.72mm, 7/1.57mm and 30/7/3.00mm

2. STANDARDS

The Conductor shall also comply in all respects with the IS: 398(Part-II)-1996 with latest amendmentsunless otherwise stipulated in this specification or any other International Standards which ensure equal orhigher quality material.

The ACSR Conductor shall also conform to the following standards.

Offersconforming to standards other than IS-398 shall be accompanied by the English version of relevantstandards in support of the guaranteed technical particulars to be furnished as per format enclosed.

3. GENERAL TECHNICAL REQUIREMENTS

The General Technical Requirements are given in Section-II. The Conductor shall conform to thesetechnical requirements.

The Bidder shall furnish guaranteed technical particulars in Section-III.

3.1. MATERIALS/WORKMANSHIP

3.1.1. The material offered shall be of best quality and workmanship. The steel cored aluminum conductor

Sl.No.

IndianStandards

Title International

1 IS:209-1979 Specification for Zinc BS-3436-19612 IS:398-1996 Specification for aluminum conductors for overhead

transmission purposes.

Part-II Aluminum conductors IEC-209-1966

Galvanized steel reinforced BS-215(Part-II)3 IS:1521-1972 Method of Tensile Testing of Steel wire ISO/R89-1959

4 IS:1778-1980 Reels and Drums for Bare conductors BS-1559-1949

5 IS:1841-1978 E.C. Grade Aluminum rod produced by rolling

6 IS:2629-1966 Recommended practice for Hot Dip Galvanizing of iron andsteel

7 IS:2633-1986 Method of testing uniformity of coating of zinc coatedarticles.

8 IS:4826-1968 Galvanized coatings on round steel wires. ASTM A472-729

9 IS:5484-1978 E.C. Grade Aluminium rod produced by continuous castingand rolling.

10 IS:6745-1972 Methods of determination of weight of zinc-coating of zinccoated iron and steel articles

BS-443-1969

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strands shall consist of hard drawn aluminum wire manufactured from not less than 99.5% pureelectrolytic aluminum rods of E.C. grade and copper content not exceeding 0.04%. They shall have thesame properties and characteristics as prescribed in IEC: 889-1987. The steel wire shall be made frommaterial produced either by the acid or basic open hearth process or by electric furnace process or basicoxygen process. Steel wire drawn from Bessemer process shall not be used.

3.1.2. The steel wires shall be evenly and uniformly coated with electrolytic high grade, 99.95% purity zinccomplying with the latest issue of IS-209 for zinc. The uniformity of zinc coating and the weight ofcoating shall be in accordance with Section-II and shall be tested and determined according to the latestIS-2633 or any other authoritative standard.

3.1.3. The steel strands shall be hot dip galvanized and shall have a minimum zinc coating of 250 gm/sq. mafter stranding. The coating shall be smooth, continuous, and of uniform thickness,free fromimperfections and shall withstand minimum three dips after stranding in standard preece test. The steelstrands shall be preformed and postformed in order to prevent spreading of strands in the event ofcutting of composite core wire. The properties and characteristics of finished strands and individual wiresshall be as prescribed in IEC: 888-1987.

4. CONDUCTOR PARAMETERS

The Parameters of individual strands and composite steel cored aluminum conductor, shall be inaccordance with the values given in Section-II.

Creep in a conductor is attributed partly due to settlement of strands and partly due to non-elasticelongation of metal when subjected to load. The manufacturer of conductor shall furnish the amount ofcreep which will take place in 10, 20, 30, 40 and 50 years along with the supporting calculations. Thecalculations should be based on everyday temperature of 32 ºC and everyday tension of 25% of UTS ofconductor of 11/33 KV Lines.

5. TOLERANCES

The tolerances on standard diameter of Aluminum and Steel wires shall be as detailed in specifictechnical requirements.

The cross-section of any wire shall not depart from circularity by more than an amount corresponding tothe tolerance on the standard diameter.

The details of diameters, lay ratios of Aluminum and steel wires shall be in accordance with the Section-II "Technical Requirements".

6. SURFACE CONDITIONS

All aluminum and steel strands shall be smooth, and free from all imperfections, spills/and splits. Thefinished conductor shall be smooth, compact, uniform and free from all imperfections including spillsand splits, die marks, scratches, abrasions, scuff marks, kinks (protrusion of wires), dents, pressmarks,cut marks, wire cross-over, over-riding looseness, pressure and/or unusual bangle noise on tapping,material inclusions, white rust, powder formation or black spots (on account of reaction with trappedrain water etc.,), dirt, grit, etc. The surface of conductor shall be free from points, sharp edges,abrasions or other departures from smoothness or uniformity of surface contour that would increaseradio interference and corona losses. When subjected to tension up to 50% of the ultimate strength ofthe conductor, the surface shall not depart from the cylindrical form nor any part of the componentparts or strands move relative to each other in such a way as to get out of place and disturb the

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longitudinal smoothness of the conductor.

7. JOINTS IN WIRES

7.1. Aluminum wires

During stranding, no aluminum wire welds shall be made for the purpose of achieving the requiredconductor length.

No joint shall be permitted in the individual aluminum wires in the outer most layer of the finishedConductor. However, joints in the 12 wire & 18 wire inner layer of the conductor are permitted butthese joints shall be made by the cold pressure butt welding and shall be such that no two such jointsshall be within 15 meters of each other in the complete stranded conductor.

7.2. Steel wires

There shall be no joints in finished steel wires forming the core of the steel reinforced aluminumconductor.

8. STRANDING

The wires used in construction of the stranded conductor, shall, before stranding, satisfy allrequirements of IS-398 (Part-II) 1996.

In all constructions, the successive layers shall be stranded in opposite directions. The wires in eachlayer shall be evenly and closely stranded round the underlying wire or wires. The outer most layer ofwires shall have a right hand lay. The lay ratio of the different layers shall be within the limits givenunder Section-II.

9. PACKING

9.1. The conductor shall be supplied in non-returnable strong wooden drums provided with lagging ofadequate strength constructed to protect the conductor against any damage and displacement duringtransit, storage and subsequent handling and stringing operations in the field. The drums shall generallyconform to IS-1778-1980 and latest version except as otherwise specified hereinafter. The conductordrums shall be adequate to wind one standard length of 2500 meters ofWEASEL/RABIT/RACOON/DOG/PANTHERACSR conductor.

9.2. The drums shall be suitable for wheel mounting and for letting off the conductor under a minimumcontrolled tension of the order of 5KN. The conductor drums shall be provided with necessary clampingarrangements so as to be suitable for tension stringing of power conductor.

9.3. The bidders should submit their drawings of the conductor drums along with the bid. After placement ofletter of intent the Manufacturer shall submit four copies of fully dimensioned drawing of the drum forEmployer's approval. After getting approval from the Employer, Manufacturer shall submit 30 morecopies of the approved drawings for further distribution and field use.

9.4. All wooden components shall be manufactured out of seasoned soft wood free from defects that maymaterially weaken the component parts of the drums. Preservative treatment for anti-termite/anti fungusshall be applied to the entire drum with preservatives of a quality which is not harmful to the conductor.

9.5. All flanges shall be 2-ply construction with 64 mm thickness. Each ply shall be nailed and clenched

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together at approximately 90 degrees. Nails shall be driven from the inside face of the flange, punchedand then clenched on the outer face. Flange boards shall not be less than the nominal thickness by morethan 2 mm. There shall not be less than 2 nails per board in each circle.

9.6. The wooden battens used for making the barrel of the conductor shall be of segmental type. These shallbe nailed to the barrel supports with at least two nails. The battens shall be closely butted and shallprovide a round barrel with smooth external surface. The edges of the battens shall be rounded orchamfered to avoid damage to the conductor.

9.7. Barrel studs shall be used for construction of drums. The flanges shall be holed and the barrel supportsslotted to receive them. The barrel studs shall be threaded over a length on either end, sufficient toaccommodate washers, spindle plates and nuts for fixing flanges at the required spacing.

9.8. Normally, the nuts on the studs shall stand protruded of the flanges. All the nails used on the innersurface of the flanges and the drum barrel shall be countersunk. The ends of the barrel shall generally beflushed with the top of the nuts.

9.9. The inner cheek of the flanges and drum barrel surface shall be painted with bitumen based paint.

9.10. Before reeling, card board or double corrugated or thick bituminized waterproof bamboo paper shall besecured to the drum barrel and inside of flanges of the drum by means of a suitable commercial adhesivematerial. The paper should be dried before use. Medium grade craft paper shall be used in between thelayers of the conductor. After reeling the conductor the exposed surface of the outer layer of conductorshall be wrapped with thin polythene sheet across the flanges to preserve the conductor from dirt, gritand damage during transportation and handling and also to prevent ingress of rain water duringstorage/transport.

9.11. A minimum space of 75 mm shall be provided between the inner surface of the external protectivelagging and outer layer of the conductor. Outside the protective lagging, there shall be minimum of twobinders consisting of hoop iron/galvanised steel wire. Each protective lagging shall have two recesses toaccommodate the binders.

9.12. Each batten shall be securely nailed across grains as far as possible to the flange edges with at least 2nails per end. The length of the nails shall not be less than twice the thickness of the battens. The nailshall not protrude above the general surface and shall not have exposed sharp edges or allow thebattens to be released due to corrosion.

9.13. The conductor ends shall be properly sealed and secured with the help of U-nails on one side of theflanges.

9.14. Only one standard length of conductor shall be wound on each drum. The method of lagging to beemployed shall be clearly stated in the tender.

9.15. As an alternative to wooden drum Bidder may also supply the conductors in non-returnable painted steeldrums. The painting shall conform to IS:9954-1981,reaffirmed in 1992. Wooden/ steel drum will betreated at par for evaluation purpose and accordingly the Bidder should quote the package.

10. LABELLING AND MARKING

The drum number shall be branded or gauged or stencilled into the flange. An arrow shall be marked onthe sides of the drum, together with the words "Roll this way". Each drum shall have the followinginformation provided on the outside of the flange stencilled with indelible ink.

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i) Manufacturer's name and address.ii) Contract/Specification number.iii) Size and type of conductor.iv) Net weight of the conductor.v) Gross weight of the conductor and drum.vi) Length of the conductor.vii) Position of the conductor end.viii) Drum and lot number.ix) Name and address of the consignee.x) Month and year of manufacture.xi) The drum may also be marked with standard specification as per which the conductor is

manufactured.

11. STANDARD LENGTHS

11.1. The standard length of the conductor shall be 2500 metres. Bidder shall indicate the standard length ofthe conductor to be offered by them. A tolerance of plus or minus 5% on the standard length offered bythe bidder shall be permitted. All lengths outside this limit of tolerance shall be treated as randomlengths.

11.2. Random lengths will be accepted provided no length is less than 70% of the standard length and totalquantity of such random length shall not be more than 10% of the total quantity order. When onenumber random length has been manufactured at any time, five (5) more individual lengths, eachequivalent to the above random length with a tolerance of +/-5% shall also be manufactured and allabove six random lengths shall be dispatched in the same shipment. At any point, the cumulativequantity supplied including such random lengths shall not be more than 12.5% of the total cumulativequantity supplied including such random lengths. However, the last 20% of the quantity ordered shall besupplied only in standard length as specified.

11.3. Bidder shall also indicate the maximum single length, above the standard length, he can manufacture inthe guaranteed technical particulars of offer. This is required for special stretches like river crossing etc.The Employer reserves the right to place orders for the above lengths on the same terms and conditionsapplicable for the standard lengths during the pendency of the Contract.

12. QUALITY ASSURANCE PLAN

A Quality Assurance Plan including customer hold points covering the manufacturing activities of thematerial shall be required to be submitted by the tenderer to the Employer along with the tender. TheQuality Assurance Plan after the same is found acceptable, will be approved by the Employer.

The contractor shall follow the approved Quality Assurance Plan in true spirit. If desired by the Employer,he shall give access to all the documents and materials to satisfy the Employer that the QualityAssurance Plan is being properly followed.

13. TESTING

13.1. SELECTION OF TEST SAMPLES FOR TYPE TESTS

13.1.1. The samples shall be taken from a continuous length of conductor and subjected to all the tests specifiedin clause 14.

13.2. SELECTION OF TEST SAMPLES FOR ACCEPTANCE TESTS

13.2.1. Before dispatch from the works individual wire and finished steel cored aluminum conductor shall be

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subjected to the tests as specified in IS:398 or any other authoritative standard.

13.2.2. Sample for individual wires for test shall be taken before stranding from outer ends of not less than tenper cent of the spools in the case of aluminum wire and ten per cent of the wire coils in the case of steelwires. If samples are taken after stranding, they shall be obtained by cutting 1.2 meters from the outerends of the finished conductor from not more than 10 per cent of the finished reels.

13.2.3. The routine tests shall be same as acceptance test and shall be carried out on each coil.

14. TESTS

The following tests shall be carried out on sample/samples of conductor.

14.1 Type Tests

(i) Visual examination(ii) Measurement of diameters of individual aluminum and steel wires.(iii) Measurement of lay ratio of each layer(iv) Breaking load test(v) Ductility test(vi) Wrapping test(vii) Resistance test on aluminum wires.(viii) DC resistance Test on Composite Conductor.(ix) Galvanizing test(x) Surface condition test(xi) Stress Strain test(xii) Procedure qualification test on welded joint of Aluminum Strands.

NOTE:-The type test reports shall not be older than FIVE years and shall be valid up to expiry ofvalidity of offer.The above additional lists if not conducted earlier, shall be done under the subject project packageat no extra cost.

14.2 Acceptance tests and Routine tests

(i) Visual and dimensional check on drum.(ii) Visual examination(iii) Measurement of diameters of individual aluminum and steel wires.(iv) Measurement of lay ratio of each layer(v) Breaking load test(vi) Ductility test(vii) Wrapping test(viii) Resistance test on aluminum wires.(ix) DC resistance Test on Composite Conductor.(x) Galvanizing test

14.3 Tests During Manufacture

The following tests during manufacture shall be carried out.

(i) Chemical analysis of zinc used for galvanising,(ii) Chemical analysis of aluminum used for making aluminum strands,

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(iii) Chemical analysis of steel used for making steel strands,

14.4 Visual examination

The conductor shall be examined visually for good workmanship and general surface finish of theconductor. The conductor drums shall be rewound in the presence of Inspecting Officer. TheInspector will initially check for Scratches, Joints etc., and that the conductor shall generally conformto the requirements of the specifications/IS 398(Part-II)-1996.

14.5 Measurement of diameters of individual Aluminum and Steel Wires.

The diameters of individual Aluminum and Steel Wires shall be checked to ensure that they conformto the requirements of this specification.

14.6 Measurement of lay-ratios

The lay-ratios of each layer of the conductor shall be measured and checked to ensure that theyconform to the requirements of this specification and IS:398 (Part-II)-1996.

14.7 Breaking load test

a) Breaking load test on complete conductor.

Circles perpendicular to the axis of the conductor shall be marked at two places on a sample ofconductor of minimum 5m length between fixing arrangement suitably fixed on a tensile testingmachine. The load shall be increased at a steady rate up to 50% of minimum specified UTS and heldfor one minute. The circles drawn shall not be distorted due to relative movement of strands.Thereafter the load shall be increased at steady rate to 100% of UTS and held for one minute. TheConductor sample shall not fail during this period. The applied load shall then be increased until thefailing load is reached and the value recorded.

b) Breaking load test on individual Aluminum and Galvanized steel wires.

This test shall be conducted on both Aluminum and Galvanized steel wires. The breaking load of onespecimen cut from each of the samples taken shall be determined by means of suitable tensile testingmachine. The load shall be applied gradually and the rate of separation of the jaws of the testingmachine shall be not less than 25 mm / min. and not greater than 100 mm. / min. The ultimatebreaking load of the specimens shall be not less than the values specified in the Section-II.

14.8 Ductility Test

For the purpose of this test both torsion and elongation tests shall be carried out on galvanized steelwires only.

14.9 Torsion Test

One specimen cut from each of the samples taken shall be gripped in two vices exactly 15 cms. apart.One of the vices shall be made to revolve at a speed not exceeding one revolution per second and theother shall be capable of moving longitudinally to allow for contraction or expansion during testing. Asmall tensile load not exceeding 2 (two) percent of the breaking load of the wire shall be applied tothe samples during testing. The test shall be continued until fracture occurs and the fracture shallshow a smooth surface at right angles to the axis of the wire. After fracture, the specimen shall be

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free from helical splits. The sample shall withstand a number of twists equivalent to not less than 18on length equal to 100 times the diameter. When twisted after stranding the number of completetwists before fracture occurs shall be not less than 16 on a length equal to 100 times the diameter ofthe wire. In case test sample length is less or more than 100 times the stranded diameter of thestrand, the minimum number of twists will be proportioned to the length and if number comes in thefraction then it will be rounded off to the next higher whole number. The fracture shall show asmooth surface at right angles to the axis of the wire.

14.10 Elongation Test

The elongation of one specimen cut from each of the samples taken shall be determined. Thespecimen shall be straightened by hand and an original gauge length of 200 mm. shall be marked onthe wire. A tensile load shall be applied as described in 1.1.4.6.2.1 and the elongation shall bemeasured after the fractured ends have been fitted together. If the fracture occurs outside the gaugemarks, or within 25 mm. of either mark and the required elongation is not obtained, the test shall bedisregarded and another test conducted. When tested before stranding, the elongation shall be notless than 4 percent and when tested after stranding, the elongation shall be not less than 3.5 percent.

14.11 Wrapping Test

This test shall be conducted on both Aluminum and Galvanized steel wires.

14.11.1 Aluminum wires

One specimen cut from each of the samples of aluminum wires shall be wrapped round a wire of itsown diameter to form a close helix of 8 turns. Six turns shall then be unwrapped and closely wrappedin the same direction as before. The wire shall not break or show any crack.

14.11.2 Galvanized steel wires

One specimen cut from each of the samples of galvanized steel wire taken shall be wrapped round amandrel of diameter equal to 4 times the wire diameter to form a close helix of 8 turns. Six turns shallthen be unwrapped and again closely wrapped in the same direction as before. The wire shall notbreak.

14.12 Resistance Test

This test shall be conducted on aluminum wires only, conforming to procedure as per IEC: 889. Theelectrical resistance of one specimen of aluminum wire cut from each of the samples taken shall bemeasured at ambient temperature. The measured resistance shall be corrected to the valuecorresponding to 20 degrees C. by means of following formula.

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R20 = RT------------------------

1+ alpha x (T-20)

Where

R20 = Resistance corrected at 20 degrees C.

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RT = Resistance measured at T degrees C.

alpha = Constant mass temperature coefficient of resistance 0.004.

T = Ambient temperature during measurementThis resistance calculated to 20 degrees C. shall be not more than the maximum value specified insection-II.

14.13 Galvanizing Test

This test shall be conducted on galvanized steel wires only. The uniformity of Zinc coating and theweight of coating shall be in accordance with IS 4826-1979.

14.14 Surface Condition Test

A sample of the finished conductor for use in 11/33 KV system having a minimum length of 5 meterswith compression type dead end clamps compressed on both ends in such manner as to permit theconductor to take its normal straight line shape, shall be subjected to a tension of 50 percent of theUTS of the conductor. The surface shall not depart from its cylindrical shape nor shall the strandsmove relative to each other so as to get out of place or disturb the longitudinal smoothness ofconductor. The measured diameter at any place shall be not less than the sum of the minimumspecified diameters of the individual aluminum and steel strands as indicated in Section-II.

14.15 Stress-Strain Test

The test is contemplated only to collect the creep data of the conductor from the manufacturer. Asample of conductor of minimum 10 meters length shall be suitably compressed with dead endclamps.

15. TEST SET-UP

15.1. The test sample shall be supported in a trough over its full length and the trough adjusted so that theconductor will not be lifted by more than 10mm under tension. This shall be ascertained by actualmeasurement.

15.2. The distance between the clamp and the sleeve mouth shall be monitored with callipers during the testto ensure that, after the test, it does not change by more than 1mm + 0.1mm from the value beforethe test.

15.3. The conductor strain shall be evaluated from the measured displacements at the two ends of thegauge length of the sample. The gauge reference targets shall be attached to the clamps which lockthe steel and aluminum wires together. Target plates may be used with dial gauges or displacementtransducers and care shall be taken to position the plates perpendicular to the conductor. Twisting theconductor, lifting it and moving it from side-to-side by the maximum amounts expected during the testshould introduce no more than 0.3mm error in the reading.

16. TEST LOADS FOR COMPLETE CONDUCTOR

The loading conditions for repeated stress-strain tests for complete conductor shall be as follows:

16.1. 1KN load shall be applied initially to straighten the conductor. The load shall be removed afterstraightening and then the strain gauges are to be set At zero tension.

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16.2. For non-continuous stress-strain data, the strain readings at 1KN intervals at lower tensions and 5 KNintervals above 30% of UTS shall be recorded.

16.3. The sample shall be reloaded to 30% of UTS and held for 1 hour. Readings are to be noted after 5, 10,15, 30, 45 and 60 minutes during the hold period. The load shall be released then after the holdperiod.

16.4. The sample shall be reloaded to 50% of UTS and held for 1 hour. Readings are to be noted after 5, 10,15, 30, 45 and 60 minutes during the hold period. The load shall be released then after the holdperiod.

16.5. Reloading up to 70% of UTS shall be done and held for 1 hour. Readings are to be noted after 5, 10,15, 30, 45 and 60 minutes. The load shall be released.

16.6. Reloading up to 85% of UTS shall be done and held for 1 hour. Readings are to be noted after 5,10,15, 30, 45 and 60 minutes and the load shall be released then.

16.7. Tension shall be applied again and shall be increased uniformly until the actual breaking strength isreached. Simultaneous readings of tension and elongation shall be recorded up to 90% of UTS at theintervals described under Clause 16.6.

17. TEST LOADS FOR STEEL CORE ONLY

The loading conditions for repeated stress-strain tests for the steel core of ACSR shall be as follows:

17.1. The test shall consist of successive applications of load applied in a manner similar to that for thecomplete conductor at 30%, 50%, 70% and 85% of UTS.

17.2. The steel core shall be loaded until the elongation at the beginning of each hold period corresponds tothat obtained on the complete conductor at 30%, 50%, 70% and 85% of UTS respectively.

18. STRESS-STRAIN CURVES

The design stress-strain curve shall be obtained by drawing a smooth curve through the 0.5 and 1hour points at 30%,50% and 70% of UTS loadings. The presence of any aluminum slack that can berelated to any observed extrusion entering the span from the compression dead ends shall beremoved from the lower ends of the design curves. Both the laboratory and standard stress-straincurves shall be submitted to the Employer along with test results. The stress-strain data obtainedduring the test shall be corrected to the standard temperature i.e. 20 deg. C.

19. DC RESISTANCE TEST ON COMPOSITE CONDUCTOR

On a conductor sample of minimum 5m length, two contact clamps shall be fixed with a pre-determined bolt torque. The resistance of the sample shall be measured by a Kelvin double bridge byplacing the clamps initially zero meter and subsequently one meter apart. The test shall be repeatedat least five times and the average value recorded. The value obtained shall be corrected to the valueat 20 deg C as per clause no. 12.8 of IS: 398 (Part-II)-1982/1996.The corrected resistance value at20 deg. C shall conform to the requirements of this specification.

20. PROCEDURE QUALIFICATION TEST ON WELDED ALUMINUM STRANDS.

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Two Aluminum wires shall be welded as per the approved quality plan and shall be subjected totensile load. The breaking strength of the welded joint of the wire shall not be less than theguaranteed breaking strength of individual strands.

21. CHEMICAL ANALYSIS OF ALUMINUM AND STEEL

Samples taken from the Aluminum and Steel ingots / coils/ strands shall be chemically/spectrographically analyzed. The same shall be in conformity with the requirements stated in thisspecification.

22. CHEMICAL ANALYSIS OF ZINC

Samples taken from the zinc ingots shall be chemically / spectrographically analysed. The same shallbe in conformity with the requirements stated in this specification.

23. VISUAL AND DIMENSIONAL CHECK ON DRUMSThe drums shall be visually and dimensionally checked to ensure that they conform to therequirements of this specification.

24. REJECTION AND RETEST

24.1. In case of failure in any type test, the Manufacturer is either required to manufacture fresh sample lotand repeat all the tests successfully once or repeat that particular type test three times successfully onthe sample selected from the already manufactured lot at his own expenses. In case a fresh lot ismanufactured for testing then the lot already manufactured shall be rejected.

24.2. If samples are taken for test after stranding and if any selected reel fails in the retest, themanufacturer may test each and every reel and submit them for further inspection. All rejectedmaterial shall be suitably marked and segregated.

25. CHECKING AND VERIFICATION OF LENGTH OF CONDUCTOR

The contractor should arrange for inspection by the representative of the Employer speciallyauthorised for this purpose. At least 50% of the total number of drums of conductor subject tominimum of two taken at random should be checked to ascertain the length of conductor.Arrangements should be made available in the works of the manufacturer for transferring theconductor from one reel to another at the same time measuring the length of the conductor sotransferred by means of a meter.

26. ADDITIONAL TESTS

The Employer reserves the right of having at his own expenses any other test(s) of reasonable naturecarried out at Bidder's premises, at site, or in any other standard Laboratory in addition to theaforesaid type, acceptance and routine tests to satisfy himself that the materials comply with thespecifications.

27. TESTING EXPENSES

27.1. The breakup of the testing charges for the type tests specified shall be indicated separately.

27.2. Bidder shall indicate the laboratories in which they propose to conduct the type test. They shall ensurethat adequate facilities are available in the laboratories and the tests can be completed in these

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laboratories within the time schedule guaranteed by them.

27.3. The entire cost of testing for the acceptance and routine tests and tests during manufacture specifiedherein shall be treated as included in the quoted unit price of the conductor, except for the expensesof the inspector/Employer's representative.

27.4. In case of failure in any type test, if repeat type tests are required to be conducted then all theexpenses for deputation of Inspector/Employer's representative shall be deducted from the contractprice. Also if on receipt of the Manufacturer's notice of testing, the Employer's representative does notfind 'plant' to be ready for testing, the expenses incurred by the Employer for redeputation shall bededucted from contract price.

28. TEST REPORTS

28.1. Copies of type test reports shall be furnished in at least six copies along with one original. One copywill be returned duly certified by the Employer only after which the commercial production of thematerial shall start.

28.2. Record of Routine test reports shall be maintained by the Manufacturer at his works for periodicinspection by the Employer's representative.

28.3. Test certificates of Tests during manufacture shall be maintained by the Manufacturer. These shall beproduced for verification as and when desired by the Employer.

29. TEST FACILITIES

The following additional test facilites shall be available at the Manufacturer's works:

(i) Calibration of various testing and measuring equipment including tensile testing machine,resistance measurement facilities, burette, thermometer, barometer, etc.

(ii) Standard resistance for calibration of resistance bridges.

(iii) Finished Conductor shall be checked for length verification and surface finish on separaterewinding machine at reduced speed(variable from 8 to 16 meters per minute).Therewinding facilities shall have appropriate clutch system and be free of vibrations, jerks etcwith traverse laying facilities.

30. INSPECTION

30.1. The Employer's representative shall, at all times, be entitled to have access to the works and all placesof manufacture where conductor shall be manufactured and the representative shall have full facilitiesfor unrestricted inspection of the Bidder's works, raw materials and process of manufacture andconducting necessary tests as detailed herein.

30.2. The Bidder shall keep the Employer informed in advance of the time of starting and of the progress ofmanufacture of conductor in its various stages so that arrangements can be made for inspection.

30.3. The contractor will intimate the Employer about carrying out of the tests at least 45 days in advance ofthe scheduled date of tests during which the Employer will arrange to depute his representative/s tobe present at the time of carrying out of the tests. Six (6) copies of the test reports shall be submitted.

16

30.4. No material shall be dispatched from its point of manufacture before it has been satisfactorilyinspected and tested, Unless the inspection is waived off by the employer in writing. In the later casealso, the conductor shall be dispatched only after satisfactory testing for all tests specified herein hasbeen completed and approved by the employer.

30.5. The acceptance of any quantity of material shall in no way relieve the Bidder of any of hisresponsibilities for meeting all requirements of the specification, and shall not prevent subsequentrejection if such material is later found to be defective.

30.6. At least 50% of the total number of drums subject to minimum of two in any lot put up for inspection,shall be selected at random to ascertain the length of conductor by the following method:

"At the works of the manufacturer of the conductor, the conductor shall be transferred from onedrum to another at the same time measuring its length with the help of a graduated pulley andCyclometer. The difference in the average length thus obtained and as declared by the Bidder in thepacking list shall be applied to all the drums if the conductor is found short during checking".

31. SCHEDULE OF DEVIATIONS/VARIATIONS

If the tenderer has any exceptions to any of the clause/s laid down in this specification, these shouldbeclearly stated in the schedule of deviations / variations.

SECTION - II

SPECIFIC TECHNICAL REQUIREMENTS

1. SCOPE

This section of the specification covers climatic and isoceraunic conditions, specific technical particulars,schedule of requirements & desired deliveries, for conductor for 11/33 kV lines.

2. 2.0

CLIMATIC & ISOCERAUNIC CONDITIONS TO BE SPECIFIED BY EMPLOYER

2.1Maximum Temperature

a) Conductor ºC.

2.2Minimum Temperature ºC.

2.3 i)Max. ambient temperature ºC

ii) Mean annual / every day temperature ºC

2.4Basic wind speed m/s

2.5Relative humidity

17

2.8 Average number of thunder storm

2.9 Altitude varying from sea level

2.10Basic horizontal Seismic Co-efficient(horizontal)

Basic vertical Seismic Co-efficient

2.11System Particulars

a) Line Voltage (kV)

b) Highest System Voltage (kV)

c) Number of Circuits

d) Frequency HZ

e) Neutral

f) Short circuit level (KA)

i) i) Maximum %

ii) Minimum %

2.6Average Rainfall (Max.) mm per annum

2.7a)Rainy months May to Sept.

15 Rainy days in a year (days)

18

3. SPECIFIC TECHNICAL REQUIREMENTS

CONDUCTOR:

1. Conductor: Rabbit/Raccoon/Dog/Weasel/Panther ACSR

2. IS applicable: IS-398 (part-II) 1996 latest revision

3. Wire Diameter Rabbit Raccoon Dog Weasel Panther

Aluminium (mm) 6/3.35 6/4.06 6/4.72 6/2.59 30/3.00

Steel(mm) 1/3.35 1/4.09 7/1.57 1/2.59 7/3.00

4. Number of strands:

Steel centre 1 1 1 1

1st steel layer - 6 6

1st Aluminium layer 6 6 6 6 12

2nd Aluminium layer 18

5. Sectional Area ofAluminium (sq. mm.)

52.88 78.83 105 31.61 212.1

6. Total SectionalArea(sq.mm.)

61.7 91.97 118.5 36.88 261.5

7. Overall diameter(mm) 10.05 12.27 14.15 7.77 21

8. Approximateweight(Kg./Km.)

10.05 12.27 14.15 7.77 21

9. Calculated D.Crersistance at 20degrees C., maximum.(Ohms/Km)

0.552 4.371 2.2792 0.9289 0.139

19

10. Ultimate tensilestrength (KN)

18.25 26.91 32.41 11.12 89.67

11. Final modulas ofelasticity (GN/sq. m)

79 79 75 79 80

12. Coefficient of linearexpansion x 10-6 per◦C

19.1 19.1 19.8 19.1 17.8

13. Lay ratio Max Min Max Min Max Min Max Min Max Min

Steel core 6 wire layer 28

13

28

13

Aluminium Ist layer 14

10

14

10

14

10

14

10

14

10

2nd layer 16

10

14. Technical Particulars

a. Diameter-mm

Standard(mm)Maximum (mm)Minimum (mm)

Rabbit Raccon Dog Weasel PantherAl Steel Al Steel Al Steel Al Steel Al Steel3.35 3.35 4.09 4.09 1.57 4.72 2.59 2.59 3.00 3.003.42 3.38 4.17 4.13 1.60 4.77 2.64 2.62 3.06 3.033.28 3.32 4.01 4.05 1.54 4.67 2.54 2.56 2.94 2.97

b. Cross-sectional area ofnominal diameter wire(mm2)

8.814 8.814 13.14 13.14 1.936 17.50 5.269 5.269 7.069 7.069

c. Weight (Kg./Km) 68.75 23.82 102.48 35.51 15.10 47.30 41.09 14.24 55.13 19.11

d. Min. breaking load (KN)

Before stranding 11.58 1.43 17.27 2.08 2.70 2.78 6.92 0.89 9.29 1.17

After Stranding 11.00 1.36 16.4 1.98 2.57 2.64 6.57 0.85 8.83 1.11

e. D.C resistance at 20C̊min. (Ohm/Km)

-3.265 -2.194 1.65 -5.49 -4.079

20

15. Zinc coating of steel core:

(i) Number of 1 minute dips: 3

(ii) Minimum weight of Zinc: 260 gms/sq m Coating

(iii) Process of Galvanizing: Hot dip.

(iv) Quality of Zinc: IS-209/1979 or latest edition.

16. Joints in strands

16.1 Steel : Not permitted

16.2 Aluminium: No joint shall be permitted in the Aluminum wires in the outer most layer of the ACSRconductor. But permitted in the inner layers such that no two such joints are within 15 meters of eachother in the complete stranded conductor.

15. Chemical composition of high carbon steel wire:

Element % Composition

i) Carbon 0.5 to 0.85ii) Manganese 0.5 to 1.10iii) Phosphorus Not more than 0.035iv) Sulphur Not more than 0.045v) Silicon 0.10 to 0.35

SCHEDULE OF LINE MATERIALS AND DESIRED DELIVERIES

POWER CONDUCTOR

Sl.No.

MATERIALDescription

Quantity(KM)

DestinationSite

Delivery to commencedelivery from the

15th month of date of Award

16/1/3.35 mm KM per month

'Rabbit' ACSRConductor


'Racoon' ACSRConductor

36/4.72+7/1.57 mm KM per month

'Dog' ACSR Conductor

21


'weasel' ACSRConductor


'panther' ACSR

Conductor

22

2. Mild Steel Channel, Angle And Flat

1) APPLICABLE STANDARDS:

The mild steel shall conform to IS: 2062 grade ‘a’ modified upto date or equivalent internationalstandard for steel materials, documents for which shall be made available at the time of inspection to theowner’s representative.

2) GENERAL REQUIREMENTS:

Material shall be supplied as per the following sizes:

100x50 ISMC channel conforming to IS: 2062 grade ‘a’ modified up to date or its equivalent InternationalStandard having length ranging from 5.5 to 13.5 meters. 75x40 ISMC channel conforming to IS: 2062grade ‘a’ modified up to date or its equivalent International Standard having length ranging from 5.5 to135 meters.

50x50x8 mm or 6 mm ISA angles conforming to IS: 2062 grade ‘a’ modified up to date or its equivalentinternational standard having length ranging from 5.5 to 13.5 meters.

45X45X5 mm ISA angles conforming to IS: 2062 grade ‘a’ modified up to date or its equivalentinternational standard having length ranging from 5.5 to 13.5 meters.

60x65x6 mm ISA angles conforming to IS: 2062 grade ‘a’ modified up to date or its equivalentinternational standard having length ranging from 5.5 to 13.5 meters.

25X3mm, 50X6mm, 50x8mm, 75X8mm and 80X8 flats conforming to IS: 2062 grade ‘a’ modified up todate or its equivalent international standard having length ranging from 5.5 to 9.5 meters.

3) GALVANISATION:

All above steel members shall be fabricated as per approved drawing having smooth edge, drilledcircular/elliptical holes of suitable measurements.

All structural steel members and bolts shall be galvanized as per IS:4759 and zinc coating shall not beless than 610gm/sq. meter for all structural steel members. All weld shall be 6mm filled weld unlessspecified otherwise. All nuts and bolt shall be of property class 5.6 of IS 1367. Plain washers shall be asper IS 2016 and spring washers shall be IS: 3063

4) INSPECTION:

All inspection/test will be carried out by representative of owner.

All tests and inspection shall be made at the place of manufacturer unless otherwise specially agreedupon by the manufacturer and the owner. The manufacturer shall provide all reasonable facilities,without charge to satisfy him that the material is being supplied in accordance with the specification.

23

3. 1.1 kV Grade Copper Stranded Control Cable

1. SCOPE:

The specification cover the design, manufacture, at manufacturer’s works, supply and delivery of CopperControl Cables screened/armoured for use indifferent EHT/HT /Grid Sub-Stations.

2 GENERAL INFORMATIONS:

The Control Cables are required for the control, protection, instrumentation, auxiliary Power Supply.Eachtender must be accompanied by full information required in the biddingschedule together with pertinentmanufacturer’s literatures, drawings, instruction manuals to enable the purchaser to make an appraisal ofthe qualityand suitability of the materials offered. Failure to comply with the provision maybe sufficientreasons to reject the bid.

3 STANDARDS AND REGULATIONS:

All materials shall comply with the applicable provisions of the latest edition of Indian Standards, IndianElectricity Rules, Indian Electricity Act and other applicable statutory provisions, rules and regulations.

The following standards would apply to the specification.

1. IS-1554 (Part-I) – PVC insulated heavy duty.

2. IS-8130-Conductors for PVC insulated Cables.

3. IS-3961 (Part-II) - Recommended current ratings for Cables.

4. IS-5831-PVC insulated and sheath of Electric Cable.

5. Other relevant standards for screening.

4 CLIMATIC AND ISOCERAUNIC CONDITIONS:

4.1 The climatic conditions at site under which the material shall operate

Satisfactory are as follows;

a) Maximum ambient temperature of the air-in shade (˚C): 50

b) Minimum temperature of the air in shade (˚C): 4

c) Maximum daily average ambient temperature (˚C): 45

d) Maximum Yearly average ambient temperature (˚C): 30

e) Maximum relative humidity (%): 100

f) Average number of thunderstorm days per annum. : 100

g) Average annual rainfall (cm): 200

h) Maximum wind pressure (Kg/M2): 150

i) Earthquake acceleration (g): 0.04 x 2 g

j) Height above Sea Level (m): Not exceeding 1000

24

4.2 The material offered shall be suitable for continuous operation at the full ratedcapacity under the aboveconditions.

5 DESIGN CRITERIA:

The Cables will be used for control protection and instrumentation, auxiliaryPower Supply connections ofthe various equipment.

5.1 The Cable will be laid in ground or on ladder type traps or drawn in conduit in ahot, humid and tropicalatmosphere. The trays may be over head, suspended orrun in concrete trenches with removable covers.The tenderer shall indicateclearly the de rating factor for the above conditions.

5.2 The maximum conductor temperature for various classes and type of cablesshall be limited to safe valueas per applicable I.S. Cables shall be marked withISI Certification Mark, if any.

6.0 SPECIFIC DESIGN REQUIREMENTS:

6.1 1100 Volts Grade Heat Resisting (HR) Copper Cables suitable for use where thecombination of ambienttemperature and temperature rise due to load results inconductor temperature not exceeding 85 deg.Cunder normal continuousoperation and 160 deg.C under short-circuit condition with strandedannealedcopper conductor, HR PVC insulated, HR extruded PVC inner sheathed, roundgalvanised steelwire armoured (for multicore cable only) and overall HRextruded PVC sheathed shall generally conformto latest revision of IS:1554(Part-I). The cores shall be colour coded as per I.S. for easy identification.

EachConductor shall consists of multi Strandscopper wire for 2.5sq.mm cross section. Conductor wireshall be stranded. The PVC material for insulation and outer sheathing shallhave smooth finish.Armouring shall be of single layer of 1.6/1.4 mm. dia. G.I.Steel Wires though enough to withstandmechanical stressed during handlingand shall be resistant to action of oil, acid and alkali. The abovecable shall beused for control, identification, inter-link and instrumentation etc.

6.2 CURRENT RATING:

The Cables will have current rating derating factors for an ambient temperature of 45 deg. C and groundcable is required to be taken into consideration. The current ratings shall be based on the maximumtemperature 85 deg. C for continuous operation at the rated current.

6.3 OPERATION:

Cables shall be capable of satisfactory operation under Power Supply System frequency variation of +5% and voltage variation of + 10%.

7 DRUM LENGTH OF CABLES:

7.1 The Cables shall be packed in non-returnable wooden drums. The wooden drums should be bearingdistinguishing number with following information duly stenciled on the outer side of one flange.

1. Name of the Manufacturer.

2. Normal sectional area of the Conductor of the Cable.

3. Number of Cores.

4. Type of Cable & Voltage for which it is suitable.

5. Length of Cable in this drum.

25

6. Direction of rotation of Drum (an arrow)

7. Gross Weight.

8. Purchase Order No. & Date.

9. Year of Manufacture.

10. Property of XXXXX (Name of Employer; DDUGJY Projects).

11. Date of Delivery.

7.2 Drums shall be proofed against attack by white ant and termite, Conforming toIS-10418-1982.

7.3 The Cables shall be supplied in Drum lengths of 250/500 Mtr. which shall besubject to tolerance of notmore than + 5% and the variation in the totalquantity of Cables due to tolerance in individual drumlength shall be limited to+ 2.5% for all types of Cable. Non-standard drum length shall not beacceptable.However, before packing the Cables on Drums, the successful bidders will berequired toobtain purchaser’s approval for the drum lengths.

7.4 Embossing on the outer sheath of the Cable with marking “Name of Employer; DDUGJY” and length ofthe Cable in meters at suitable intermittent distance, preferably 1Mtr.should be done.

8 DRAWING DATA &MANUAL:

The following information shall be furnished in triplicate along with the tenders:

a) Manufacturer’s leaflets giving construction details, dimensions and characteristics of differentCables.

b) Current rating of cables including derating factor due to grouping, ambient temperature and Typeof various installations.

c) Write up sketch illustrating the manufacturer’s recommendation for splitting, jointing andtermination of different type of cables.

d) List of customers to whom the cable for similar rating has been supplied.

9 TESTS:

9.1 Routine tests in accordance with the provision of relevant standard specification shall be carried out foreach drum of finished cable lengths. Type Tests and acceptance tests on the samples taken on randombasis from the lot of cables offered for inspection shall have to be carried out as per relevant IndianStandard Specification to prove the general qualities and design of a given type of cable and for thepurpose of acceptance of the lot.

TYPE TEST REPORTS for the type tests conducted in accordance with IS:1554(Part-I for similar type ofCables (as per Tender Specification) Type Test Report conducted on similar type of Cable from NABL/Central Govt./ approved Accredited Testing Laboratory within 5 years is to be submitted.

9.2 WITNESSING OF TESTS:

The tabulation for each test result shall contain corresponding I.S. specified limiting figures to facilitatechecking of test Results. Six (6) copies of type tests certificate lot-wise for each type of cables should besent to the Employer for acceptance. Type Test Certificate for each lot and routine test certificate foreach drum of cables shall be submitted to the Employer for approval before dispatch of cables from theWorks. The test certificates shall be completed with all results.

26

4. 11kV Porcelain Insulators and FittingsPart-I : INSULATORS

1. SCOPE

This specification covers details of porcelain insulators (Pin and Strain Insulators) for use on 11 KVoverhead power lines in rural electric distribution system.

2. APPLICABLE STANDARDS

Except when it conflicts with the specific requirements of this specification, the insulators shall complywith IS:731 and IS:3188 as amended from time to time.

3. GENERAL REQUIREMENTS

3.1 The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed.

3.2 Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the porcelainparts of insulators except those areas which serve as support during firing or are left unglazed for thepurpose of assembly.

3.3 The design of insulators shall be such that stresses due to expansion and contraction in any part of theinsulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal.

3.4 Cement used in construction of insulators shall not cause fracture by expansion or loosening bycontraction and proper care shall be taken to locate the individual parts correctly during cementing.The cement shall not give rise to chemical reaction with metal fittings and its thickness shall be asuniform as possible.

3.5 The insulators should preferably be manufactured in automatic temperature - controlled kilns toobtain uniform baking and better electrical and mechanical properties.

4. CLASSIFICATION AND DIMENSIONS

4.1 Both pin and strain insulators shall conform to Type B of IS:731.

4.2 The dimensions of pin insulators shall be as shown in Fig. 1.

4.3 The strain insulators shall be of Ball and Socket type or Tongue and Clevis type, as required by thePurchaser. The dimensions of these insulators shall be as per Fig. 2.

5. TEST VOLTAGES

5.1 The test voltages of insulators shall be as under:

27

HighestSystemvoltage

VisibleDischargeTest

Wet Power Frequencywithstand Test

Power Frequency puncturewithstand test

Impulse voltagewithstand Test

Pin Insulator StrainInsulator

KV(rms) KV(rms) KV(rms) KV(rms) KV(rms) KV(Peak)

12 9 35 105

1.3 times ofthe actualdry flash

over voltageof the

Insulator

75

6. FAILING LOAD

6.1 Mechanical Failing Load (For Pin Insulators only) The insulators shall be suitable for a minimumfailing load of 5 KN applied in transverse direction.

6.2 Electro-Mechanical Failing Load (For Strain Insulators) The insulators shall be suitable for a minimumfailing load of 45 KN applied axially.

7. CREEPAGE DISTANCE

The minimum creepage distance shall be as under :

Highest SystemVoltage

Normal and Moderatelypolluted atmosphere

Heavily Polluted atmosphere

Pin insulator Strain insulator

KV mm mm Mm

12 230 320 400

Note : Higher value of creepage distance has been specified for strain

insulators as these are normally used in horizontal position in 11 KV lines.

8. TESTS

The insulators shall comply with the following tests as per IS:731 :-

8.1 Type Tests

a) Visual examination

b) Verification of dimensions

c) Visible discharge test

d) Impulse Voltage Withstand Test

e) Wet Power Frequency Voltage Withstand Test

f) Temperature cycle test

g) Mechanical Failing load test (for Pin Insulators only) to be carried out as per procedure described atSub-clause 8.4

h) 24-hour Mechanical strength Test for Strain Insulators

28

i) Puncture Test

j) Porosity Test

k) Galvanising Test

l) Electro-mechanical failing load test (for Strain insulators only) to be carried out as per proceduredescribed at Sub-clause 8.4.

m) Thermal Mechanical Performance Test (for Strain insulators only) to be carried out as per proceduredescribed at Sub-clause 8.4

8.2 ROUTINE TESTS:

a) Visual examination

b) Mechanical routine test (for strain insulator only)

c) Electrical routine test (for strain insulator only)

d) Hydraulic Internal Pressure test on shells for strain insulators to be carried out as per proceduredescribed at Sub-clause 8.4

8.3 ACCEPTANCE TEST:

a) Verification of Dimensions

b) Temperature cycle Testc) Electro-mechanical failing load test (for strain insulators only) to be carried out as per proceduredescribed at Sub-clause 8.4d) Puncture test (for strain insulators only)e) Porosity testf) Galvanising test

8.4 Following procedure shall be used for conducting tests on insulators :

1 Hydraulic Internal Pressure Test on Shells (For Disc Insulators)

The test shall be carried out on 100% shells before assembly. The detail and methodology forconducting this test has been illustrated at attached Annexure – 1.

2 Thermal Mechanical Performance Test (if applicable)

Thermal Mechanical Performance Test shall be performed in accordance with IEC- 383-1-1993Clause 20 with the following modifications:

(1) The applied mechanical load during this test shall be 70% of the rated electromechanical ormechanical value.

(2) The acceptance criteria shall be

(a) X greater than or equal to R + 3S.WhereX- Mean value of the individual mechanical failing load.R- Rated electro-mechanical / mechanical failing load.S- Standard deviation.

(b) The minimum sample size shall be taken as 20 for disc insulator units.

29

(c) The individual electromechanical failing load shall be at least equal to the rated value. Alsopuncture shall not occur before the ultimate fracture.

3 Electromechanical/Mechanical Failing Load Test.

This test shall be performed in accordance with clause 18 and 19 of IEC 383 with thefollowingacceptance

(i) X greater than or equal to R + 3S , WhereX- Mean value of the electro-mechanical/mechanical/ failing load.R- Rated electro-mechanical / mechanical failing load.S- Standard deviation.

(ii) The minimum sample size shall be taken as 20 for disc insulators units. However, for larger lot size,IEC 591 shall be applicable.

(iii) The individual electro-mechanical/mechanical failing load shall be at least equal to the rated value.Also electrical puncture shall not occur before the ultimate fracture.

9. MARKING

9.1 Each insulator shall be legibly and indelibly marked to show the following :

a) Name or trade mark of manufacturer

b) Month and year of manufacture

c) Minimum failing load in KN

d) ISI certification mark, if any

9.1.1 Markings on porcelain shall be printed and shall be applied before firing.

10. PACKING

All insulators (without fittings) shall be packed in wooden crates suitable for easy but rough handlingand acceptable for rail transport. Where more than one insulator is packed in a crate, woodenseparators shall be fixed between the insulators to keep individual insulators in positionwithout movement within the crate.

11. INSPECTION

11.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreedupon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford theinspector representing the purchaser all reasonable facilities, without charge, to satisfy him that thematerial is being furnished in accordance with this specification.

11.2 The purchaser has the right to have the tests carried out at his own cost by an independent agencywhenever there is dispute regarding the quality of supply.

30

Part-II : INSULATOR FITTINGS

1. SCOPE

This specification covers details and test requirements for (i) Pins for 11 KV Insulators, (ii) HelicallyFormed Pin Insulator Ties (iii) Fittings forStrain Insulatorswith Helically Formed Conductor Dead-Endsand (iv) Fittings for Strain Insulators with conventional Dead-End Clamps.


Pins shall comply with the requirements of IS:2486 (Pt.I & II). Helically formed fittings shall complywith IS:12048-1987. Fittings for strain insulators shall comply with the requirements of IS:2486Pt.I toIV.

3. PINS FOR INSULATORS

3.1 General Requirements

The pins shall be of single piece obtained preferably by the process of forging. They shall not be made byjoining, welding, shrink fitting or any other process using more than one piece of material. The pins shallbe of good finish, free from flaws and other defects. The finish of the collar shall besuch that a sharp angle between the collar and the shank is avoided. All ferrous pins, nuts and washers,except those made of stainless steel, shall be galvanised. The threads of nuts and taped holes, when cutafter galvanising shall be well oiled or greased.

3.2 Dimensions

Pins shall be of small steel head type S 165 P as per IS:2486 (Part-II) having stalk length of 165mmand shank length of 150mm with minimum failing load of 5 KN. Details of the pins are shown in Fig. 3.

3.3 Tests

Insulator pins shall comply with the following test requirements as per IS:2486 (Part-I)-1993 or latestversion thereof:

3.3.1. Type Tests

a) Checking of threads on heads

b) Galvanising test

c) Visual examination test

d) Mechanical test

3.3.2 Acceptance Tests

a) Checking of threads on heads

b) Galvanising test

c) Mechanical test

3.3.3 Routine Test

Visual examination test

31

4. HELICALLY FORMED PIN INSULATOR TIES

4.1 Helically formed ties used for holding the conductor on the pin insulator (Fig.4) shall be made ofaluminium alloy or aluminised steel or aluminium-clad steel wires and shall conform to therequirements of IS:12048-1987.

4.2 The ties shall be suitable for pin insulator dimensions as per Fig. 1 of Pt. I and conductor sizes to bespecified by the purchaser.

Note : Helically formed insulators ties are made to suit specific sizes of conductors, which should be clearlyspecified by the purchaser.

4.3 Elastomer pad for insulator shall be used with the ties to avoid abrasion of the conductor coming intodirect contact with the insulator.

4.4 Tests

The ties shall be subjected to the tests specified in IS:12048-1987.

5. FITTINGS FOR STRAIN INSULATORS WITH HELICALLY FORMED CONDUCTOR DEAD-ENDGRIPS

5.1 Fittings for Strain Insulators of Tongue & Clevis Type

5.1.1 The fittings shall consist of the following components:

a) Cross arm strap conforming to IS: 2486 (Pt.II)-1989.

b) Aluminium alloy die cast thimble-clevis for attaching to the tongue of strain insulatoron one end and for accommodating the loop of the helically formed dead-end fittingattheother end initssmoothinternal contour. The thimble shall be suitable for allsizes of conductorsranging from 7/2.11mm to 7/3.35mm ACSR. The thimble clevis shall be attached to

the insulator by a steel cutter pin used with a non-ferrous split pin of brassor stainless steel. The thimble shall have clevis dimensions as per IS:2486 (Pt.II)-1989.

c) Helically formed dead-end grip having a pre-fabricated loop to fit into the grooved contour of thethimble on one end and for application over the conductorat the other end. The formed fittingshall conform to the requirement of IS:12048-1987.

Note : As the helically formed fittings are made to suit specific sizes conductors, thepurchase should clearly specify the number of fittings required for each size of conductor.

5.1.2 Nominal dimensions of the T&C type insulator fittings are shown in Fig. 5.

5.2 Fittings for Strain Insulators of Ball & Socket Type

5.2.1 The fittings shall consist of the following components:

a) Cross arm strap conforming to IS:2486 (Pt.II)-1989.

b) Forged steel ball eye for attaching the socket end of the strain insulator to the cross armstrap. Forgingsshall be made of steel as per IS:2004-1978.

32

c) Aluminium alloy thimble-socket made out of permanent mould cast, high strength aluminium alloyfor attaching to the strain insulator on one end and for accommodating the loop of the helicallyformed dead-end fittings at the other end in its smooth internal contour. The thimble-socket shallbe attached to the strain insulator with the help of locking pin as per the dimensions given inIS:2486 (Pt.II)-1989 and

d) Helically formed dead-end grip as per clause 5.1.1(c) above.

5.2.2 Nominal dimensions of the Ball & Socket type insulator fittings are shown in Fig. 6.

5.3 Tests

The helically formed fittings for strain insulators shall be subjected to tests as per IS:12048-1987. Theother hardware fittings shall be tested as per IS:2486 (Part-I).

6. FITTINGS FOR STRAIN INSULATORS WITH CONVENTIONAL DEAD-END CLAMPS ALTERNATIVE TO FITTINGS COVERED IN CLAUSE 5)

6.1 Fittings for strain insulators with conventional dead-end clamps for use with tongue & clevis or ball &socket type insulators shall consist of the following components :

a) Cross arms strap conforming to IS:2486 (Pt.II)-1989

b) Dead-end clamp made of aluminium alloy to suit ACSR conductors from 7/2.11mm to7/3.35mm. The ultimate strength of the clamp shall not be less than 3000 Kg. The shape andmajor dimensions of clamps suitable for B&S and T&C insulators are shown in figures 7 & 8respectively.

6.2 Tests

The fittings shall be subjected to type, routine and acceptance tests in accordance with the stipulationsof IS:2486 (Pt.I).

Note: Fittings for strain insulators as stipulated in Clause 5 are preferable to the fittings stipulated inClause 6 both from the point of view of better quality of construction and ease of application.

7. PACKING

7.1 For packing of GI pins, strain clamps and related hardware, double gunny bags or wooden cases shall beused. The heads and threaded portions of pins and the fittings shall be properly protected againstdamage.

7.2 The gross weight of the packing shall not normally exceed 50 Kg. Helicallyformed fittings shall be packed in card-board / wooden boxes. Fittings for differentsizes of conductors shall be packed in different boxes and shallbe complete with their minor accessories fitted in place and colour codes on tags/fittings shall bemarked to identify suitability for different sizes of conductors as per IS:12048-1987.

8 . INSPECTION

8.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreedupon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford theinspector representing the purchaser all reasonable facilities, without charge, to satisfy him that thematerial is being furnished in accordance with this specification.

33

8.2 The purchaser has the right to have the test carried out at his own cost by an independent agencywhenever there is dispute regarding the quality of supply.

ANNEXURE-I

HYDRAULIC PRESSURE TEST ON DISC INSULATOR SHELL

120 KG C/ M sq +/- 10 on the shell before cap and pinassembly to check the integrity of Porcelain

40

5. 11 kV/22 kV/33 kV Composite Insulators

1) SCOPE :

This specification covers the design, manufacture, testing and supply of 11KV / 22KV / 33 KV CompositeInsulators. The composite insulators shall be of the following type:

i) Long rod insulators for conductors in tension application at angle / cut points the insulators shallbe of tongue & clevis type.

ii) Line post insulators or pin insulators for straight line locations

2) SERVICE CONDITIONS :

The insulators to be supplied against this specification shall be suitable for satisfactory continuousoperation under the following tropical conditions.

Maximum ambient temperature (Degree C) … 50Minimum ambient temperature (Degree C) … 3.5

Relative Humidity (%) … 10 to 100Maximum Annual Rainfall (mm) … 1450

Maximum Wind pressure (kg/m.sq.) … 150Maximum wind velocity (km/hour) … 45

Maximum altitude above mean sea level (meter) … 1000Isoceraunic level (days/year) … 50

Seismic level (Horizontal acceleration) … 0.3 gModerately hot and humid tropical climate Conductive to rust

and fungus growth

3) SYSTEM PARTICULARS:

a) Nominal System Voltage 11 kV 22 kV 33 kV

b) Corresponding highest system Voltage 12 kV 24kV 36 kVc) Frequency 50 Hz with 3% tolerance

d) Number of phase 3 3 3e) Neutral earthing effectively grounded.

4) STANDARDS :

Unless otherwise specified elsewhere in the specifications insulators shall confirm to the latest revisionsof all relevant standards available at the time of placement of the order. The standards are listed inAnnexure ‘A’.

5) GENERAL REQUIREMENTS

i) The composite insulators shall generally conform to latest Standards as listed in Annexure ‘A’

ii) The Composite Insulators will be used on lines on which the conductors will be A.A.A. Conductor of sizeup to 200 sq. mm. and ACSR of any size up to Panther (0.2 sq. inch copper equivalent). The insulators

41

should withstand the conductor tension, the reversible wind load as well as the high frequency vibrationsdue to wind.

iii) Supplier must be an indigenous manufacturer and manufacturer of composite insulators of rating 33 kVor above OR must have developed proven in house technology and manufacturing process for compositeinsulators of above rating OR possess technical collaboration /association with a manufacturer ofcomposite insulators of rating 33kV or above. The Manufacturer shall furnish necessary evidence insupport of the above, which can be in the form of certification from the utilities concerned, or any otherdocuments to the satisfaction of the Employer.

iv) Insulator shall be suitable for both the suspension and strain type of load & shall be of tongue & clevistype. The diameter of Composite Insulator shall be less than 200 mm. The center-to-center distancebetween tongue & clevis shall be max. 300 mm for 11 kV, 450 mm for 22 kV & 550 mm for 33 kVcomposite Insulator.

v) Insulators shall have sheds with good self-cleaning properties. Insulator shed profile, spacing, projectionetc. and selection in respect of polluted conditions shall be generally in accordance with therecommendation of IEC-60815/IS: 13134.

vi) The size of Composite insulator, minimum creepage distance and mechanical strength along withhardware fittings shall be as follows:

Sr.No.

Type ofCompositeinsulators

NominalSystemVoltagekV (rms)

HighestSystemVoltagekV(rms )

VisibleDischarge

TestVoltagekV(rms)

Wet PowerFrequencyWithstandVoltagekV(rms)

ImpulseWithstand

voltagekV(rms)

MinimumCreepageDistance

(mm)(HeavilyPolluted

25mm/kV)

Center toCenter

DistanceBetweenTongue&Clevis(mm)

Min.FailingloadkN

ShedDiameter (mm)( min)

i.Long Rodinsulator

11 12 9 35 75 320 300 45 100

22 24 18 55 125 600 450 70 100

33 36 27 75 170 900 550 70 100

ii.Post/PinInsulator

11 12 9 35 75 320 522 24 18 55 125 560 1033 36 27 75 170 900 10

vii) Dimensional Tolerance of Composite InsulatorsThe tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed as followsin line with-IEC 61109:

(0.04d+1.5) mm when d≤300mm.(0.025d+6) mm when d>300 mm.Where, d being the dimensions in millimeters for diameter, length or creepage distance as the case maybe. However no negative tolerance shall be applicable to creepage distance.

viii) Interchangeability:The composite insulator together with the tongue & clevis fittings shall be of standard design suitable foruse with the hardware of any other indigenous make conforming to relevant standards referred above.

ix) Corona and RI PerformanceAll surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be subjected toexcessive localized pressure. The insulator and metal parts shall be so designed and manufactured that itshall avoid local corona formation and not generate any radio interference beyond specified limit underthe operating conditions.

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6) TECHNICAL DESCRIPTION OF COMPOSITE INSULATORS

Polymeric Insulators shall be designed to meet the high quality, safety and reliability and are capable ofwithstanding a wide range of environmental conditions.Polymeric Insulators shall consist of THREE parts, at least two of which are insulating parts:-(a) Core- the internal insulating part(b) Housing- the external insulating part(c) Metal end fittings.

i) COREIt shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod). Glass fibers and resin shallbe optimized in the FRP rod. Glass fibers shall be Boron free electrically corrosion resistant (ECR) glassfiber or Boron free E-Glass and shall exhibit both high electrical integrity and high resistance to acidcorrosion. The matrix of the FRP rod shall be Hydrolysis resistant. The FRP rod shall be manufacturedthrough Pultrusion process. The FRP rod shall be void free.

ii) HOUSING:The FRP rod shall be covered by a seamless sheath of a silicone elastometric compound or silicone alloycompound of a thickness of 3mm minimum. It shall be one-piece housing using Injection MoldingPrinciple to cover the core. The elastomer housing shall be designed to provide the necessary creepagedistance and protection against environmental influences. Housing shall conform to the requirements ofIEC 61109/92-93 with latest amendments

iii) WEATHERSHEDS

The composite polymer weather sheds made of a silicone elastometric compound or silicone alloycompound shall be firmly bonded to the sheath, vulcanized to the sheath or molded as part of the sheathand shall be free from imperfections It should protect the FRP rod against environmental influences,external pollution and humidity. The weather sheds should have silicon content of minimum 30% byweight. The strength of the weather shed to sheath interface shall be greater than the tearing strengthof the polymer. The interface, if any, between sheds and sheath (housing) shall be free from voids.

iv) METAL END FITTINGS:

End fitting transmit the mechanical load to the core. They shall be made of spheroidal graphite cast iron,malleable cast iron or forged steel or aluminum alloy. They shall be connected to the rod by means of acontrolled compression technique. Metal end fittings shall be suitable for tongue & clevis hard wares ofrespective specified mechanical load and shall be hot dip galvanized after, all fittings have beencompleted. The material used in fittings shall be corrosion resistant. As the main duty of the end fittingsis the transfer of mechanical loads to the core the fittings should be properly attached to the core by acoaxial or hexagonal compression process & should not damage the individual fibers or crack the core.The gap between fitting and sheath shall be sealed by a flexible silicone elastomeric compound orsilicone alloy compound sealant. System of attachment of end fitting to the rod shall provide superiorsealing performance between housing, i.e. seamless sheath and metal connection. The sealing must bemoisture proof. The dimensions of end fittings of insulators shall be in accordance with the standarddimensions stated in IEC: 60120/ IS: 2486 - Part-II /1989.

7) WORKMANSHIP

7.1 All the materials shall be of latest design and conform to the best engineering practices adopted in thehigh voltage field. Manufacturers shall offer only such insulators as are guaranteed by them to besatisfactory and suitable for continued good service in power transmission lines.

7.2 The design, manufacturing process and material control at various stages shall be such as to givemaximum working load, highest mobility, best resistance to corrosion, good finish and elimination ofsharp edges and corners.

43

7.3 The design of the insulators shall be such that stresses due to expansion and contraction in any part ofthe insulator shall not lead to deterioration.

7.4 The core shall be sound and free of cracks and voids that may adversely affect the insulators.

7.5 Weather sheds shall be uniform in quality. They shall be clean, sound, smooth and shall be free fromdefects and excessive flashing at parting lines.

7.6 End fittings shall be free from cracks, seams, shrinks, air holes and rough edges. End fittings should beeffectively sealed to prevent moisture ingress; effectiveness of sealing system must be supported by testdocuments. All surfaces of the metal parts shall be perfectly smooth with out projecting points orirregularities, which may cause corona.

All load bearing surfaces shall be sooth and uniform so as to distribute the loading stresses uniformly.

7.7 All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent to 610gm/sq.m. or 87 microm thickness and shall be in accordance with the requirement of IS:4759. the zincused for galvanizing shall be of purity 99.5% as per IS:4699. The zinc coating shall be uniform, adherent,smooth, reasonably bright continuous and free from imperfections such as flux, ash rust stains, bulkywhite deposits and blisters. The galvanized metal parts shall be guaranteed to withstand at least foursuccessive dips each lasting for one (1) minute duration under the standard preece test. The galvanizingshall be carried out only after any machining.

8) TESTS AND STANDARDS

Insulators offered shall be manufactured with the same configuration & raw materials as used in theinsulators for which design & type test reports are submitted. The manufacturer shall submit a certificatefor the same. The design & type test reports submitted shall not be more than five years old.

8.1 DESIGN TESTS :

For polymeric insulators it is essential to carry out design test as per clause 4.1 of IEC 61109 / 92-93with latest amendments. The design tests are intended to verify the suitability of the design, materialsand method of manufacture (technology). When a composite insulator is submitted to the design tests,the result shall be considered valid for the whole class of insulators, which are represented by the onetested and having the following characteristics:

• Same materials for the core, and sheds and same manufacturing method;• Same material of the fittings, the same design, the same method of attachment;

Same or greater layer thickness of the shed material over the core (including a sheath where used );• Same or smaller ratio of the highest system voltage to insulation length;• Same or smaller ratio of all mechanical loads to the smallest core diameter between fittings• Same or greater diameter of the core.

The tested composite insulators shall be identified by a drawing giving all the dimensions with themanufacturing tolerances.Manufacturer should submit test reports for Design Tests as per IEC – 61109 (clause – 5). Additionallyfollowing tests shall be carried out or reports for the tests shall be submitted after award of contract:UV test: the test shall be carried out in line with clause 7.2 of ANSI C29.13.

8.2 TYPE TESTS :

The type tests are intended to verify the main characteristics of a composite insulator. The type tests

44

shall be applied to composite insulators, the class of which has passed the design tests.

8.2.1 Following Type test shall be conducted on a suitable number of individual insulator units, components,materials or complete strings:

SI. Description of type test Test procedure / standard

No1 Dry lightning impulse withstand voltage test As per IEC 61109(Clause 6.1)

2 Wet power frequency test As per IEC 61109(Clause 6.2)

3 Mechanical load-time test As per IEC 61109(Clause 6.4)4 Radio interference test As per IEC 61109(Clause 6.5)

revised5 Recovery of Hydrophobicity test Annexure – B This test may be

repeated every 3yrsby the manufacturer

6 Chemical composition test for silicon content Annexure – B Or any other testmethod acceptable to

the Employer7 Brittle fracture resistance test Annexure – B

The Manufacturer shall submit type test reports as per IEC 61109. Additional type tests required if anyshall be carried out by the manufacturer, after award of contract for which no additional charges shall bepayable. In case, the tests have already been carried out, the manufacturer shall submit reports for thesame.

8.3 ACCEPTANCE TESTS :

The test samples after having withstood the routine test shall be subject to the following acceptancetests in order indicated below:

(a) Verification of dimensions : Clause 7.2 IEC: 61109,(b) Verification of the locking system : Clause 7.3 IEC: 61109,

(if applicable)(c) Verification of tightness of the interface : Clause 7.4 IEC: 61109

Between end fittings & Insulator housing amendment 1of 1995(d) Verification of the specified : Clause 7.4 IEC: 61109,

mechanical load amendment 1of 1995(e) Galvanizing test : IS:2633/IS:6745

8.4 ROUTINE TESTS:

Sr.No. Description Standard1 Identification of marking As per IEC: 61109 Clause 8.1

2 Visual Inspection As per IEC: 61109 Clause 8.2

3 Mechanical routine test As per IEC: 61109 Clause 8.3

Every polymeric insulator shall withstand mechanical routine test at ambient temperature tensile load atRTL corresponding to at least 50 % of the SML for at least 10 sec.

45

8.5 TESTS DURING MANUFACTURE:

Following tests shall also be carried out on all components as applicable(a) Chemical analysis of zinc used for galvanizing(b) Chemical analysis, mechanical, metallographic test and magnetic particle inspection for malleable

castings.(c) Chemical analysis, hardness tests and magnetic particle inspection for forgings.

8.6 SAMPLE BATCH FOR TYPE TESTING :

The Manufacturer shall offer material for sample selection for type testing only after getting QualityAssurance Plan approved by Employer. The sample for type testing will be manufactured strictly inaccordance with the approved Quality Assurance Plan.

9) QUALITY ASSURANCE PLAN :

9.1 The Manufacturer shall submit following information:

i) Test certificates of the raw materials and bought out accessories.

ii) Statement giving list of important raw material, their grades along with names of sub-Manufacturers forraw materials, list of standards according to which the raw materials are tested. List of tests normallycarried out on raw materials in presence of Manufacturer’s representative.

iii) List of manufacturing facilities available.

iv) Level of automation achieved and lists of areas where manual processing exists.

v) List of areas in manufacturing process, where stage inspections are normally carried out for qualitycontrol and details of such tests and inspections.

vi) List of testing equipments available with the Manufacturer for final testing of equipment along with validcalibration reports.

vii) The manufacturer shall submit Manufacturing Quality Assurance Plan (QAP) for approval& the same shall be followed during manufacture and testing.

9.2 The Manufacturer shall submit the routine test certificates of bought out raw materials/accessories andcentral excise passes for raw material at the time of inspection.

9.3 The Employer’s representative shall at all times be entitled to have access to the works and all places ofmanufacture, where insulator, and its component parts shall be manufactured and the representativesshall have full facilities for unrestricted inspection of the Manufacturer’s and sub-Manufacturer’s works,raw materials, manufacture of the material and for conducting necessary test as detailed herein.

9.4 The material for final inspection shall be offered by the Manufacturer only under packed condition. TheEmployer shall select samples at random from the packed lot for carrying out acceptance tests. The lotoffered for inspection shall be homogeneous and shall contain insulators manufactured in 3-4consecutive weeks.

9.5 The Manufacturer shall keep the Employer informed in advance of the time of starting and the progressof manufacture of material in their various stages so that arrangements could be made for inspection.

46

9.6 No material shall be dispatched from its point of manufacture before it has been satisfactorily inspectedand tested unless the Employer in writing waives off the inspection. In the later case also the materialshall be dispatched only after satisfactory testing specified herein has been completed.

9.7 The acceptance of any quantity of material shall in no way relieve the Manufacturer of his responsibilityfor meeting all the requirements of the specification and shall not prevent subsequent rejection, if suchmaterial are later found to be defective

10) TEST CERTIFICATE :

The manufacturerer shall furnish detailed type test reports of the offered composite Insulators as perclause 8.2 of the Technical Specifications at the NABL approved laboratories to prove that the compositeInsulators offered meet the requirements of the specification. These Type Tests should have been carriedout within five years prior to the date of opening of this manufacturer

The Employer reserves right to demand repetition of some or all the Type Test in presence of Employer’srepresentative. For this purpose, the manufacturerer shall quote unit rates for carrying out each TypeTest. However, such unit rates will not be considered for evaluation of the offer. In case the unit fails inthe Type Tests, the complete supply shall be rejected.

11) TESTING FACILITIES :

The manufactirer must clearly indicate what testing facilities are available in the works of themanufacturer and whether facilities are adequate to carry out all Routine & acceptance Tests. Thesefacilities should be available to Employer's Engineers if deputed or carry out or witness the tests in themanufacturer works. The insulators shall be tested in accordance with the procedure detailed in IEC61109 / 92-93 with latest amendments.

12) DRAWINGS :

(i) The Manufacturer shall furnish full description and illustration of the material offered.

(ii) The Manufacturer shall furnish the outline drawing (3 copies) of each insulator unit including a crosssectional view of the long rod insulator unit. The drawing shall include but not be limited to the followinginformation:

Long rod diameter with manufacturing tolerancesMinimum Creepage distance with positive toleranceProtected creepage distanceEccentricity of the long rod unit

Axial run outRadial run out

Unit mechanical and electrical characteristicsSize and weight of ball and socket/tongue & clevisWeight of composite long rod unitsMaterialsIdentification markManufacturer’s catalogue number

(iii) After placement of award the Manufacturer shall submit fully dimensioned insulator crate drawing fordifferent type of insulators for approval of the Employer.

13) RETEST AND REJECTION:

13.1 Sample Procedure for testing of insulators shall be as per clause 7.1 to 7.6 of IEC 61109 for Acceptance

47

& Routine Tests.

For the sampling tests, two samples are used, E1and E2. The sizes of these samples are indicated in thetable below.

Lot Size (N)Sample Size

E1 E2

N < 300 Subject to agreement

300 < N < 2000 4 3

2000< N < 5000 8 4

5000< N < 10000 12 6

If more than 10000 insulators are concerned, they shall be divided into an optimum number of lotscomprising between 2000 and 10000 insulators. The results of the tests shall be evaluated separately foreach lot.

The insulators shall be selected by the Employer’s representative from the lot at random.

The samples shall be subjected to the applicable sampling tests.The sampling tests are:Verification of dimensions - (E1 + E2)

Verification of the locking system - (E2)

Verification of tightness of the interface between - (E2)

end fittings & Insulator housing

Verification of the specified mechanical load SML - (E1)

Galvanizing test - (E2)

In the event of a failure of the sample to satisfy a test, the retesting procedure shall be as follows :

If only one insulator or metal part fails to comply with the sampling tests, a new sample equal to twicethe quantity originally submitted to the tests shall be subjected to retesting. The retesting shall comprisethe test in which failure occurs. If two or more insulator or metal parts fail to comply with any of thesampling tests or if any failure occurs during the retesting, the complete lot is considered as notcomplying with this standard and shall be withdrawn by the manufacturer.Provided the cause of the failure can be clearly identified, the manufacturer may sort the lot to eliminateall the insulators with these defects. The sorted lot then be resubmitted for testing. The number thenselected shall be three times the first chosen quantity for tests. If any insulators fail during this retesting,the complete lot is considered as not complying with this standard and shall be withdrawn by themanufacturer.

13.2 Verification of dimensions (E1 + E2)

The dimensions given in the drawings shall be verified. The tolerances given in the drawing are valid. Ifno tolerances are given in the drawings the values mentioned in this specification shall hold good.

13.3 Verification of the locking system (E2)

This test applies only to the insulators equipped with socket coupling as specified by IEC 120 and isperformed according to IEC 383.

13.4 Verification of tightness of the interface between end fittings & Insulator housing (E2)

48

One insulator selected randomly from the sample E2, shall be subjected to crack indication by dyepenetration, in accordance with ISO 3452,on the housing in the zone embracing the complete length ofthe interface between the housing and metal fitting and including an additional area, sufficientlyextended beyond the end of the metal part.The indication shall be performed in the following way.(i) the surface shall be properly pre-cleaned with the cleaner ;(ii) the penetrant, which shall act during 20 minutes, shall be applied on the cleaned surface;(iii) with in 5 minutes after the application of the penetrant, the insulator shall be subjected, at the

ambient temperature, to a tensile load of 70 % of the SML, applied between the metal fittings; thetensile load shall be increased rapidly but smoothly from zero up to 70 % of the SML, and thenmaintained at this value for 1 minute;

(iv) the surface shall be cleaned with the excess penetrant removed, and dried;(v) the developer shall be applied if necessary;(vi) the surface shall be inspected.

Some housing materials may be penetrated by the penetrant. In such cases evidence shall be providedto validate the interpretation of the results.

After the 1 min. test at 70 % of the SML, if any cracks occur, the housing and, if necessary, the metalfittings and the core shall be cut, perpendicularly to the crack in the middle of the widest of the indicatedcracks, into two halves. The surface of the two halves shall then be investigated for the depth of thecracks.

13.5 Verification of the specified mechanical load SML

The insulators of the sample E1 shall be subjected at ambient temperature to a t ensile load, appliedbetween the couplings. The tensile load shall be increased rapidly but smoothly from zero toapproximately 75 % of the SML, and then be gradually increased to the SML in a time between 30 sec.to 90 sec.

If 100 % of the SML is reached in less than 90 s, the load (100 % of the SML) shall be maintained forthe remainder of the 90 s. (This test is considered to be equivalent to a 1min withstand test at the SML.)The insulators have passed the test at 13.4 & 13.5 above if:No failure (breakage or complete pull out of the core, or fracture of the metal fitting) occurs either duringthe 1 min. 70 % withstand test (a) or during the 1 min.100 % withstand test (b).No cracks are indicated after the dye penetration method described in 13.4 above.The investigation of the halves described in 13.4 above shows clearly that the cracks do not reach thecore.

13.6 Galvanizing testThis test shall be performed according to IS: 2633/IS: 6745 on galvanized parts.

14) MARKINGS :

14.1 Each insulator shall be legibly and indelibly marked with the following details as per IEC- 61109:a) Name or trademark of the manufacturer.b) Voltage & Typec) Month and year of manufacturing.d) Min. failing load/guaranteed mechanical strength in kilo Newton followed by the word ‘KN’ to facilitateeasy identification.e) DDUGJY ‘Employer Name’. Marking

14.2 One 10 mm thick ring or 20 mm thick spot of suitable quality of paint shall be marked on the end fittingof each composite long rod of particular strength for easy identification. The paint shall not have anydeteriorating effect on the insulator performance.

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Following codes shall be used as identification mark:

For 45 KN long rod units : BlueFor 70 KN long rod units : Red

15) PACKING :

15.1 All insulators shall be packed in strong corrugated box of min. 7 ply duly paletted or wooden crates. Thegross weight of the crates along with the material shall not normally exceed 100 Kg to avoid hacklingproblem. The crates shall be suitable for outdoor storage under wet climate during rainy season.

15.2 The packing shall be of sufficient strength to withstand rough handling during transit, storage at site andsubsequent handling in the field.

15.3 Suitable cushioning, protective padding, or Dunn age or spacers shall be provided to prevent damage ordeformation during transit and handling.

15.4 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destinationand to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing andfaulty or illegible markings. Each wooden case /crate /corrugated box shall have all the markingsstenciled on it in indelible ink.

15.5 The Manufacturer shall provide instructions regarding handling and storage precautions to be taken atsite.

16) GUARANTEE

The Manufacturer of insulators shall guarantee overall satisfactory performance of the insulators. Themanufacturerer shall furnish in the form attached (Schedule 'A') all the guaranteed technical particulars.

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SCHEDULE – A1

GUARANTEED TECHNICAL PARTICULARS.

COMPOSITE INSULATOR UNIT

11KV(45KN) / 11KV(70KN),(to be filled separately for each type mentioned above)

Sr.No Parameter Name Parameter type

1. Type of insulator Text

2. Standard according to which the insulators manufactured and tested Text

3. Name of material used in manufacture of the insulator with class/grade

3.1 Material of core (FRP rod)Texti) E-glass or ECR-glass

ii) Boron content

3.2 Material of housing & weather sheds Text(Silicon content by weight)

3.3 Material of end fittings Text

3.4 Sealing compound for end fitting Text

4.0 Colour Text

5. Electrical characteristics

5.1. Nominal system voltage KV (rms) Numeric

5.2 Highest system voltage KV (rms) Numeric

5.3 Dry Power frequency withstand voltage KV (rms) Numeric

5.4 Wet Power frequency withstand voltage KV (rms) Numeric

5.5 Dry flashover voltage KV (rms) Numeric

5.6 Wet flash over voltage KV (rms) Numeric

5.7 Dry lighting impulse withstand voltage Numerica) Positive KV (peak)

b) Negative KV (peak)

5.8 Dry lighting impulse flashover voltage Numerica) Positive KV (peak)b) Negative KV (peak)

5.9 RIV at 1 MHz when energized at Numeric10 kV/ 30 kV (rms) under dry condition Micro volts

6.0 Creepage distance (Min.) (320mm) (mm) Numeric

6.1 Center to center distance between tongue & clevis) (300mm) (mm) Numeric

6.2 Shed diameter (100mm) (mm) Numeric

7.0 Mechanical characteristics: KN NumericMinimum failing load

8.0 Dimensions of insulator

8.1 Weight Kg Numeric

51


8.2 Dia. of FRP rod: mm Numeric

8.3 Length of FRP rod mm Numeric

8.4 Dia. of weather sheds (100mm) mm Numeric

8.5 Thickness of housing mm Numeric

8.6 Dry arc distance mm Numeric

8.7Dimensioned drawings of insulator (including weight with tolerances in weight)

enclosed. Boolean

9.0.Method of fixing of sheds to housing (Specify): Single mould or Modular construction

(Injection molding / compression molding) Text

10.0 No of weather sheds Text

11.0 Type of sheds

11.1 Aerodynamic Text

11.2 With underribs Text

12. Packing details

12.1 Type of packing Text

12.2 No. of insulators in each pack Text

12.3 Gross weight of package Text

13.0 Design Test Report, Type Test Report of insulator enclosed. Boolean

14.0 Any other particulars which the Manufacturer may like to give File

52

SCHEDULE – A2



22KV (70KN)




3. Name of material used in manufacture of the insulator withclass/grade

3.1 Material of core (FRP rod) Texti) E-glass or ECR-glassii) Boron content

3.2 Material of housing & weather sheds Text(silicon content by weight )



4.0 Colour Text








5.7 Dry lighting impulse withstand voltage Numerica) Positive KV (peak)b) Negative KV (peak)

5.8 Dry lighting impulse flashover voltage Numerica) Positive KV (peak)



6.0 Creepage distance (Min.) mm Numeric

6.1 Center to center distance between tongue & clevis (mm) Numeric

6.2 Shed diameter (mm) Numeric




53




8.4 Dia. of weather sheds mm Numeric



8.7 Dimensioned drawings of insulator (including weight with Booleantolerances in weight) enclosed.

9.0. Method of fixing of sheds to housing (Specify): Single mould or TextModular construction (Injection molding / compression molding)


11.0 Type of sheds



12. Packing details






54

SCHEDULE – A3



33KV (70KN)




3. Name of material used in manufacture of the insulator withclass/grade

3.1 Material of core (FRP rod ) Texti) E-glass or ECR-glassii) Boron content

3.2 Material of housing & weather sheds Text(silicon content by weight )



4.0 Colour Text








5.7 Dry lighting impulse withstand voltage Numerica) Positive KV (peak)b) Negative KV (peak)

5.8 Dry lighting impulse flashover voltage Numerica) Positive KV (peak)



6.0 Creepage distance (Min.) mm Numeric

6.1 Center to center distance between tongue & clevis (mm) Numeric

6.2 Shed diameter (mm) Numeric




55




8.4 Dia. of weather sheds mm Numeric



8.7 Dimensioned drawings of insulator (including weight with Booleantolerances in weight) enclosed.

9.0. Method of fixing of sheds to housing (Specify): Single mould or TextModular construction (Injection molding / compression molding)


11.0 Type of sheds



12. Packing details






56

ANNEXURE ‘A’

STANDARDS TO BE ADOPTED FOR COMPOSITE INSULATORS

Sr.No.

IndianStandard

TitleInternational

Standard

1 -Definition, test methods and acceptance criteria for composite insulators for

A.C. overhead lines above 1000VIEC: 61109

2 IS: 731Porcelain insulators for overhead power lines with a nominal voltage greater

than 1000VIEC: 60383

3 IS: 2071 Methods of High Voltage Testing IEC: 60060-1

4 IS: 2486Specification for Insulator fittings for Overhead power Lines with a nominal

voltage greater than 1000V General Requirements and TestsDimensional Requirements Locking Devices

IEC: 60120 IEC:60372

5. -Thermal Mechanical Performance test and mechanical performance test on

string insulator unitsIEC: 60575

6. IS: 13134 Guide for the selection of insulators in respect of polluted condition IEC: 608157. - Characteristics of string insulator units of the long rod type IEC: 60433

8. - Hydrophobicity Classification GuideSTRI guide

1.92/1

9. -Radio interference characteristics of overhead power lines and high-voltage

equipment.CISPR: 18-2 Part

210. IS: 8263 Methods of RI Test of HV insulators IEC: 60437

11.Standard for Insulators- Composite-Distribution Dead-end Type

ANSI C29.13-2000

12. IS: 4759 Hot dip zinc coatings on structural steel & other allied productsISO: 1459 ISO:

146113. IS: 2629 Recommended Practice for Hot, Dip Galvanization for iron and steel ISO: 1461 (E)14. IS: 6745 Determination of Weight of Zinc Coating on Zinc coated iron and steel articles ISO: 146015. IS: 3203 Methods of testing of local thickness of electroplated coatings ISO: 217316. IS: 2633 Testing of Uniformity of Coating of zinc coated articles17. - Standard specification for glass fiber strands ASTM D 578-0518. - Standard test method for compositional analysis by Thermogravimetry ASTM E 1131-03

19. IS:4699Specification for refined secondary Zinc

57

Annexure-B

Tests on Insulator units

1 RIV Test (Dry)The insulator string along with complete hardware fittings shall have a radio interference voltage levelbelow 100 micro volts at one MHz when subjected to 50 Hz AC voltage of 10kV & 30 kV for 11 kV & 33kV class insulators respectively under dry condition. The test procedure shall be in accordance withIS:8263 /IEC:437/CISPR 18-2.

2 Brittle Fracture Resistance TestBrittle fracture test shall be carried out on naked rod along with end fitting by applying “1n HNO3 acid”(63 g conc. HNO3 added to 937 g water) to the rod. The rod should be held 80% of SML for theduration of the test. The rod should not fail within the 96-hour test duration. Test arrangement shouldensure continuous wetting of the rod with Nitric acid.

3 Recovery of Hydrophobicity & Corona test

The test shall be carried out on 4mm thick samples of 5cm X 7cm.

i. The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the surface todry and spray with water. Record the Hydrophobicity classification in line with STRI guide forHydrophobicity classification. Dry the sample surface.

ii. The sample shall be subjected to mechanical stress by bending the sample over a groundelectrode. Corona is continuously generated by applying 12 kV to a needle like electrodeplaced 1mm above the sample surface. The test shall be done for 100 hrs.

iii. Immediately after the corona treatment, spray the surface with water and record the HCclassification. Dry the surface and repeat the corona treatment as at clause 2 above. Note HCclassification. Repeat the cycle for 1000 hrs. or until an HC of 6 or 7 is obtained. Dry thesample surface.

iv. Allow the sample to recover and repeat hydrophobicity measurement at several time intervals.Silicone rubber should recover to HC 1 – HC 2 within 24 to 48 hours, depending on thematerial and the intensity of the corona treatment.

4 Chemical composition test for Silicon content

The content of silicon in the composite polymer shall be evaluated by EDX (Energy Dispersion X- ray)Analysis or Thermo-gravimetric analysis. The test may be carried out at CPRI or any other NABLaccredited laboratory.

58

6. 33 & 11 kV Station Class Lightning Arrestor & 11 kV Distribution Class Surge Arrestors

1. 33kV VOLTAGE CLASS SURGE ARRESTORS

Lightning Arrestors at Grid Substation shall be of Station class only in 33 & 11 KV System.

1.1. INTRODUCTIONThe section covers the specification of 33kV voltage level, 10 kA, and Station class heavy duty, gaplessmetal (zinc) oxide Surge Arrestors complete with insulating base, terminal clamps, complete fittings &accessories for installation on outdoor type 33kV switchgear/transmission lines / transformers.

1.2. STANDARDSThe design, manufacture and performance of Surge Arrestors shall comply with IS: 3070 Part-3 andother specific requirements stipulated in the specification. Unless otherwise specified, the equipment,material and processes shall conform to the latest applicable Indian/International Standards as listedhereunder:

IS:2071-1993 (Part-1)

Methods of High Voltage Testing General Definitions& Test Requirements.

IS:2071-1974(Part-2) Test ProceduresIS:2629-1985 Recommended Practice for hot dip galvanizing on

Iron & SteelIS:2633-1986 Method for Testing uniformity of coating of zinc

coated Articles.IS:3070-1993 (Part –3)

Specification for surge arrestor for alternating currentsystems. Metal-Oxide lightening Arrestors withoutgaps

IS:4759-1996 Specification for hot dip zinc coating on StructuralSteel and Other allied products.

IS:5621-1980 Hollow Insulators for use in Electrical Equipment.IS:6209-1982 Methods of Partial discharge measurement.

IS:6745 Method for determination of mass of zinc coating onzinc coated iron and steel articles

ANSI/IEEE-C.62.11 Metal oxide, Surge Arrestor for AC Power Circuits.IEC –60099-4 Surge Arrestors

The equipment complying with any other internationally accepted standards shall also be consideredif it ensures performance equivalent to or superior to the Indian Standards.

1.3. GENERAL REQUIREMENT1.3.1. The metal oxide gap less Surge Arrestor without any series or shunt gap shall be suitable for protection of

33kV switchgear, transformers, associated equipment and 33 kV lines from voltage surges resulting fromnatural disturbance like lightning as well as system disturbances.

1.3.2. The surge arrestor shall draw negligible current at operating voltage and at the same time offerleast resistance during the flow of surge current.

1.3.3. The surge arrestor shall consist of non-linear resistor elements placed in series and housed in electricalgrade porcelain housing / silicon polymeric of specified creepage distance.

59

1.3.4. The assembly shall be hermetically sealed with suitable rubber gaskets with effective sealing systemarrangement to prevent ingress of moisture.

1.3.5. The surge arrestor shall be provided with line and earth terminals of suitable size. The ground sideterminal of surge arrestor shall be connected with 25x6 mm galvanized strip, one end connectedto the surge arrestor and second end to a separate ground electrode. The bidder shall alsorecommend the procedure which shall be followed in providing the earthing system to the Surge Arrestor.

1.3.6. The surge arrestor shall not operate under power frequency and temporary over voltage conditions butunder surge conditions, the surge arrestor shall change over to the conducting mode.

1.3.7. The surge arrestor shall be suitable for circuit breaker performing 0-0.3sec.-CO-3 min-CO- duty in thesystem.

1.3.8. Surge arrestors shall have a suitable pressure relief system to avoid damage to the porcelain/siliconpolymeric housing and providing path for flow of rated fault currents in the event of arrestor failure.

1.3.9. The reference current of the arrestor shall be high enough to eliminate the influence of grading and straycapacitance on the measured reference voltage.

1.3.10. The arrestors for 33 kV system shall be suitable for mounting on transformers, Bus, Line & structure as perscheme. The supplier shall furnish the drawing indicating the dimensions, weights etc. of the surgearrestors for the design of mounting Structure.

1.3.11. The arrestor shall be capable of handling terminal energy for high surges, external pollution and transientover voltage and have low losses at operating voltages.

1.4. ARRESTOR HOUSING

1.4.1. The arrestor housing shall be made up of porcelain/silicon polymeric housing and shall be homogenous,free from laminations, cavities and other flaws of imperfections that might affect the mechanical anddielectric quality. The housing shall be of uniform brown (for porcelain)/Grey (for silicon polymeric)colour, free from blisters, burrs and other similar defects.

Arrestors shall be complete with fasteners for stacking units together and terminal connectors.

1.4.2. The housing shall be so coordinated that external flashover shall not occur due to application of anyimpulse or switching surge voltage up to the maximum design value for arrestor. The arrestors shall notfail due to contamination. The 33 kV arrestors housing shall be designed for pressure relief class as givenin Technical Parameters of the specification.

1.4.3. Sealed housings shall exhibit no measurable leakage.

1.5. FITTINGS & ACCESSORIES

1.5.1. The surge arrestor shall be complete with fasteners for stacking units together and terminal connectors.

1.5.2. The terminals shall be non-magnetic, corrosion proof, robust and of adequate size and shall be so locatedthat incoming and outgoing connections are made with minimum possible bends. The top metal cap andbase of surge arrestor shall be galvanized. The line terminal shall have a built in clamping device whichcan be adjusted for both horizontal and vertical take off.

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1.6. TESTS

1.6.1. Test on Surge ArrestorsThe Surge Arrestors offered shall be type tested and shall be subjected to routine and acceptancetests in accordance with IS : 3070 (Part-3)/IEC-60099-4. In addition, the suitability of the surge arrestersshall also be established for the followings

i) Acceptance testsa) Measurement of power frequency reference voltage of arrester units.b) Lightning impulse residual voltage on arrester units (IEC clause 6.3.2)c) Internal ionization or partial discharge test

ii) Special Acceptance tests

a) Thermal stability test (IEC 99-4clause 7.2.2)b) Watt loss test.

iii) Routine testsa) Measurement of reference voltageb) Residual voltage test of arrester unitc) Internal ionization or partial discharge testd) Sealing teste) Verticality check on completely assembled surge arresters as a sample test on each lot if

applicable.

iv) Type Tests

Following shall be type test as per IS 3070 (Part 3): 1993 or its latest amendment.

1. Insulation Withstand test

a) Lightning Impulse

b) Power Frequency (Dry/Wet)

2.

Residual Voltage Test

a) Steep current impulse residual voltage test

b) Lightning impulse residual voltage test

c) Switching Impulse Residual voltage test

3.

Long duration current impulse withstand test

4.

Switching surge operating duty test

5.

Power frequency voltage Vs. Time characteristics

6.

Accelerated Ageing test

61

7.

Pressure relief test

a) High Currentb) Low Current

8.

Artificial pollution test (for porcelain housing)

9.

Seismic Test

10.

Partial Discharge test

11.

Bending test

12.

a) Temperature cycle test (for porcelain housing)

b) Porosity test (for porcelain housing)

13.

Galvanising test on metal parts

14.

Seal Leakage test (for porcelain housing)

15.

Seal leak test and operation tests ( for surgemonitor)

16.

Weather ageing test (for polymer housing)

1.6.2. The maximum residual voltages corresponding to nominal discharge current of 10 kA for steepcurrent, impulse residual voltage test, lightning impulse protection level and switching impulse level shallgenerally conform to Annex-K of IEC-99-4.

1.6.3. The contractor shall furnish the copies of the type tests and the characteristics curves between theresidual voltage and nominal discharge current of the offered surge arrestor and power frequencyvoltage v/s time characteristic of the surge arrestor subsequent to impulse energy consumptionas per clause 6.6.7 of IS:3070 (Part-3) offered along with the GTP/Drawing.

1.6.4. The surge arrestor housing shall also be type tested and shall be subjected to routine and acceptance testsin accordance with IS: 5621.

1.6.5. Galvanization Test

All Ferrous parts exposed to atmospheric condition shall have passed the type tests and be subjected toroutine and acceptance tests in accordance with IS:2633 & IS 6745.

1.7. NAME PLATE

1.7.1. The name plate attached to the arrestor shall carry the following information:

62

- Rated Voltage

- Continuous Operation Voltage

- Normal discharge current

- Pressure relief rated current

- Manufacturers Trade Mark

- Name of Sub-station

- Year of Manufacturer

- Name of the manufacture

- Name of Client-“ “

- Purchase Order Number along with date

1.8. DRAWINGS AND INSTRUCTION MANUALS

Within 15 days of receipt of the order, the successful tenderer shall furnish to the purchaser the followingdrawings and literature for approval:

(i) Outline dimensional drawings of Surge Arrestor and all accessories.(ii) Assembly drawings and weights of main component parts.(iii) Drawings of terminal clamps.(iv) Arrangement of earthing lead.(v) Minimum air clearance to be maintained of line components to ground.(vi) Name plate(vii) Instructions manual(viii) Drawing showing details of pressure relief valve(ix) Volt-time characteristics of surge arrestors(x) Detailed dimensional drawing of porcelain housing/Silicon polymeric i.e. internal diameter,

external diameter, thickness, height, profile, creepage distance, dry arcing distance etc.

1.9. TECHNICAL PARTICULARS

1.9.1. The surge arrestors shall conform to the following standard technical requirements. The Insulation valuesshall be enhanced considering the altitude of operation & other atmospheric conditions.

System Parameters:

Nominal system voltage : 33 kVHighest system voltage : 36 kVSystem earthing : Solidly earthed system

Frequency (Hz) : 50Lightning Impulse withstand Voltage (kVP) : 170

63

Power frequency withstand Voltage (kV rms) : 70Connection to system : Phase to earth

1.9.2. Surge Arrestors

Type of Surge Arrestor : Gapless Metal oxide outdoor

Arrestor rating (kV rms) : 30Continuous Operating voltage (kV rms) : 25Standard Nominal Discharge Current Rating (kA)

(8x20 micro impulse shape): 10

Line discharge class : 2

Degree of protection : IP-67

Lightning Impulse at 10 kA : 85

Partial discharge at 1.05 COV not greater than : 50 (PC)Energy capability corresponding toa) Arrestor rating (kj/kV) : 4.5

b) COV (kJ/kV) : 4.9

Peak current for high current impulse operatingduty of arrestor classification 10 kA

: 100

1.9.3. Insulator Housing

Power frequency withstand test voltage(wet) (kV rms)

: 70

Lightning impulse withstand/tests voltage (kVP) : 170

Pressure Relief Class : 40Creepage distance not less than : 900 mm

1.9.4. GalvanisationFabricated Steel Aticles-- 5 mm thick cover : 610 g/m2

-- Under 5 mm but not less than 2mm thickness

: 460 g/m2

-- Under 2 mm but not less than 1.2mm thickness

: 340 g/m2

Castings-- Grey Iron, malleable iron : 610 g/m2

Threaded works other than tubes &tube fittings

-- Under 10 mm dia 270 g/m2

-- 10 mm dia & above 300 m2

2. 11kV VOLTAGE CLASS SURGE ARRESTORS

64

2.1. INTRODUCTION

This section covers the specification of 11kV voltage station Surge Arrestors for installation on outdoor type11kV switchgear, transmission lines, transformers etc. 11kV side of which is not enclosed in a cable box.Station class surge arrestors shall be complete with fasteners for stacking units.

2.2. STANDARDS

The design, manufacture and performance of Surge Arrestors shall comply with IS: 3070 Part-3 andother specific requirements stipulated in the specification. Unless otherwise specified, the equipment,material & processes shall conform to the latest amendments of the following:

IS:2071-1993 (Part-1) Methods of High Voltage Testing General Definitions &Test Requirements.

IS:2071-1974 (Part-2) Test Procedures.IS: 2629-1985 Recommended Practice for hot dip galvanizing on Iron &

Steel.IS: 2633-1986 Method for Testing uniformity of coating of zinc coated

Articles.IS:3070-1993 (Part – 3) Specification for surge arrestor for alternating current

systems. Metal-Oxide lightening Arrestors withoutgaps.

IS: 4759-1996 Specification for hot dip zinc coating on structural steeland other allied products.

IS: 5621-1980 Hollow Insulators for use in Electrical Equipment.IS: 6209-1982 Methods of Partial discharge measurement.IS: 6745 Method for determination of mass of zinc coating on zinc

coated iron and steel articles.ANSI/IEEE-C.62.11 Metal oxide, Surge Arrestor for AC Power Circuits.IEC –60099-4 Surge Arrestors.

The equipment complying with any other internationally accepted standards shall also be consideredif it ensures performance equivalent to or superior to the Indian Standards.

2.3. GENERAL REQUIREMENT

2.3.1. The metal oxide gap less Surge Arrestor without any series or shunt gap shall be suitable for protection of11 kV side of power transformers, associated equipment and 11kV lines from voltage surges resulting fromnatural disturbance like lightning as well as system disturbances.


2.3.3. The surge arrestor shall consist of non-linear resistor elements placed in series and housed in electricalgrade porcelain housing / silicon polymeric of specified Creepage distance.


65

2.3.5. The surge arrestor shall be provided with line and earth terminals of suitable size. The ground sideterminal of surge arrestor shall be connected with 25x6 mm galvanized strip, one end connectedto the surge arrestor and second end to a separate ground electrode. The bidder shall alsorecommend the procedure which shall be followed in providing the earthing system to the Surge Arrestor.


2.3.7. The surge arrestor shall be suitable for circuit breaker performing 0-0.3 min-CO-3 min-CO- duty in thesystem.

2.3.8. Surge arrestors shall have a suitable pressure relief system to avoid damage to the porcelain/ siliconpolymeric housing and providing path for flow of rated fault currents in the event of arrestor failure.


2.3.10. The Surge Arrestor shall be thermally stable and the bidder shall furnish a copy of thermal stability testwith the bid.


2.3.12. The surge arrestor shall be provided with line and earth terminals of suitable size.


2.4.1. The arrestor housing shall be made up of porcelain/silicon polymeric housing and shall be homogenous,free from laminations, cavities and other flaws of imperfections that might affect the mechanical anddielectric quality. The housing shall be of uniform brown (for porcelain)/Grey (for silicon polymeric)colour, free from blisters, burrs and other similar defects.

Arrestors shall be complete with fasteners for stacking units together and terminal connectors.

2.4.2. The housing shall be so coordinated that external flashover shall not occur due to application of anyimpulse or switching surge voltage upto the maximum design value for arrestor. The arrestors shall not faildue to contamination. The 11kV arrestors housing shall be designed for pressure relief class as given inTechnical Parameters of the specification.


2.5. ARRESTOR MOUNTING

The arrestors shall be suitable for mounting on 4 pole/2 pole structure used for pole/plinth mountedtransformer and for incoming and outgoing lines. Arrestor may also be required to be mounted on abracket provided in the Transformers.


2.6.1. The surge arrestor shall be complete with fasteners and terminal connectors.

66


2.7. TESTS

2.7.1. Test on Surge Arrestors

The Surge Arrestors offered shall be type tested and shall be subjected to routine and acceptancetests in accordance with IS : 3070 (Part-3)-/IEC:600994. In addition, the suitability of the surge arrestersshall also be established for the followings.

i) Acceptance testsa) Measurement of power frequency reference voltage of arrester units.b) Lightning impulse residual voltage on arrester units (IEC clause 6.3.2)c) Internal ionization or partial discharge test

ii) Special Acceptance tests:a) Thermal stability test (IEC clause 7.2.2)b) Watt loss test.

iii) Routine testsa) Measurement of reference voltageb) Residual voltage test of arrester unitc) Internal ionization or partial discharge testd) Sealing teste) Verticality check on completely assembled surge arresters as a sample test on each lot if

applicable.

iv) Type TestsFollowing shall be type test as per IS 3070 (Part 3): 1993 or its latest amendment


a) Lightning Impulse

b) Power Frequency (Dry/Wet)2. Residual Voltage Test

a) Steep current impulse residual voltage test

b) Lightning impulse residual voltage test

c) Switching Impulse Residual voltage test3. Long duration current impulse withstand test

4. Switching surge operating duty test

5. Power frequency voltage Vs. Time characteristics

6. Accelerated Ageing test

7. Pressure relief test

c) High Currentd) Low Current

67

8. Artificial pollution test (for porcelain housing)

9. Seismic Test

10. Partial Discharge test

11. Bending test

12. a) Temperature cycle test (for porcelain housing)

b) Porosity test (for porcelain housing)13. Galvanising test on metal parts

14. Seal Leakage test (for porcelain housing)

15. Seal leak test and operation tests ( for surge monitor)

16. Weather ageing test (for polymer housing)

2.7.2. The maximum residual voltages corresponding to nominal discharge current of 10 kA for steepcurrent, impulse residual voltage test, lightning impulse protection level and switching impulse level shallgenerally conform to Annex-K of IEC-99-4.

2.7.3. The contractor shall furnish the copies of the type tests and the characteristics curves between theresidual voltage and nominal discharge current of the offered surge arrestor and power frequencyvoltage v/s time characteristic of the surge arrestor subsequent to impulse energy consumptionas per clause 6.6 of IS:3070 (Part-3) offered alongwith the bid.

2.7.4. The surge arrestor housing shall also be type tested and shall be subjected to routine and acceptancetests in accordance with IS :5621.

2.7.5. Galvanization TestAll Ferrous parts exposed to atmospheric condition shall have passed the type tests and be subjected toroutine and acceptance tests in accordance with IS:2633 & IS 6745.

2.8. NAME PLATE


- Rated Voltage



- Pressure relief rated current

68


- Name of Sub-station



- Name of Client-


2.9. DRAWINGS AND INSTRUCTION MANUALSWithin 15 days of receipt of the order, the successful tenderer shall furnish to the purchaser, the followingdrawings and literature for approval:

(i) Outline dimensional drawings of Surge Arrestor and all accessories.(ii) Assembly drawings and weights of main component parts.(iii) Drawings of terminal clamps.(iv) Arrangement of earthing lead.(v) Minimum air clearance to be maintained of line components to ground.(vi) Name plate(vii) Surge monitor, if applicable.(viii) Instructions manual(ix) Drawing showing details of pressure relief valve(x) Volt-time characteristics of surge arrestors(xi) Detailed dimensional drawing of porcelain housing/Silicon polymeric i.e. internal diameter, external

diameter, thickness, height, profile, creepage distance, dry arcing distance etc.



System Parameters

i) Nominal system voltage 11kV

ii) Highest system voltage 12 kV

iii) System earthing Effectively earthed system

iv) Frequency (Hz) 50

v) Lightning Impulse withstand 75 Voltage (kVP)

vi) Power frequency withstand 28 Voltage (kV rms)

vii) Arrestor duty-- Connection to system Phase to earth-- Type of equipment to be protected transformers & switchgear

69

2.10.2. Surge Arrestors

i) Type Gapless Metal oxide outdoor

ii) Arrestor rating (kV rms) 9

iii) Continuous Operating voltage 7.65 (kV rms)iv) Standard Nominal Discharge Current 10 Rating (kA) (8x20 micro impulse shape)

v) Degree of protection IP 67

vi) Line discharge Class 2

vii) Steep current at 10 kA 45

viii) Lightning Impulse at 10 kA 40

ix) Energy capability corresponding toa) Arrestor rating (kj/kV) 4.5b) COV (kj/kV) 4.9

x) Peak current for high current 100impulse operating duty of Standard TS fo

arrestor classification10 kA

2.10.3. Insulator Housing

i) Power frequency withstand test voltage (Wet) (kV rms) 28ii) Lightning impulse withstand/tests voltage (kVP) 75

2.10.4. Galvanisation

i) Fabricated Steel Aticlesa) 5 mm thick cover 610 g/m2

b) Under 5 mm but not less than 2 mm thickness 460 g/m2

c) Under 2 mm but not less than 1.2 mm thickness 340 g/m2

ii) CastingsGrey Iron, malleable iron 610 g/m2

iii) Threaded works other than tubes & tube fittingsa) Under 10 mm dia 270 g/m2

b) 10 mm dia & above 300 g/m2

NOTE- Surge Monitor shall have to be provided if coverded in BPS.

3. DISTRIBUTION CLASS SURGE ARRESTORS

To be used in distribution Transformer Substations only.

3.1. INTRODUCTION

This section covers the specification of Distribution class Surge Arrestor for 11kV transmission lines,transformers etc.

70

3.2. STANDARDSThe design, manufacture and performance of Surge Arrestors shall comply with IS: 3070 Part-3 andother specific requirements stipulated in the specification. Unless otherwise specified, the equipment,material and processes shall conform to the latest applicable Indian/International Standards as listedhereunder:

IS:2071- 1993 (Part-1)Requirements.

: Methods of High Voltage Testing General Definitions & Test

IS:2071-1974 (part-2) : Test Procedures

IS:2629-1985 : Recommended Practice for hot dip galvanizing on Iron &Steel

IS:2633-1986 : Method for Testing uniformity of coating of zinc coatedArticles.

IS3070-1993 (Part–3) : Specification for surge arrestor for alternating currentsystems. Metal-Oxide lightening Arrestors withoutgaps

IS:4759-1996 : Specification for hot dip zinc coating on Structural Steel andOther allied products.

IS:5621-1980 Hollow Insulators for use in Electrical Equipment.IS:6209-1982 Methods of Partial discharge measurement.

IS:6745 Method for determination of mass of zinc coating on zinccoated iron and steel articles

ANSI/IEEE-C.62.11 : Metal oxide, Surge Arrestor for AC Power (1982)Circuits.

IEC –60099-4 Surge Arrestors

3.2.1. The equipment complying with any other internationally accepted standards shall also be consideredif it ensures performance equivalent to or superior to the Indian Standards.

3.3. GENERAL REQUIREMENT

3.3.1. The metal oxide gap less Surge Arrestor without any series or shunt gap shall be suitable for protection of11 kV side of Distribution Transformers, associated equipment and 11 kV lines from voltage surgesresulting from natural disturbance like lightning as well as system disturbances.


3.3.3. The surge arrestor shall consist of non-linear metal oxide resistor elements placed in series and housed inelectrical grade porcelain housing / silicon polymeric of specified Creepage distance.


3.3.5. The surge arrestor shall be provided with line and earth terminals of suitable size. The ground sideterminal of surge arrestor shall be connected with 25x6 mm galvanized strip, one end connectedto the surge arrestor and second end to a separate ground electrode. The contractor shall alsorecommend the procedure which shall be followed in providing the earthing/system to the Surge Arrestor.

71


3.3.7. The surge arrestor shall be suitable for circuit breaker performing 0-0.3 min-CO-3 min-CO- duty in thesystem.


3.3.9. The Surge Arrestor shall be thermally stable and the contractor shall furnish a copy of thermal stability testwith the bid.



3.4.1. The arrestor housing shall be made up of porcelain/silicon polymeric housing and shall be homogenous,free from laminations, cavities and other flaws of imperfections that might affect the mechanical anddielectric quality. The housing shall be of uniform brown (for porcelain)/ Grey (for silicon polymeric)colour, free from blisters, burrs and other similar defects.

3.4.2. The housing shall be so coordinated that external flashover shall not occur due to application of anyimpulse or switching surge voltage upto the maximum design value for arrestor. The arrestors shall not faildue to contamination.


3.5. ARRESTOR MOUNTING

The arrestors shall be suitable for mounting on 4 pole/2 pole structure used for pole mounted transformerand for incoming and outgoing lines.


3.6.1. The surge arrestor shall be complete with disconnector and terminal connectors and all other accessories.


3.7. TESTS

3.7.1. Test on Surge Arrestors

The Surge Arrestors offered shall be type tested and shall be subjected to routine and acceptancetests in accordance with IS : 3070 (Part-3)-1993. In addition, the suitability of the surge arresters shallalso be established for the followings

a) Acceptance tests:i) Measurement of power frequency reference voltage of arrester units.ii) Lightning impulse residual voltage on arrester units (IEC clause 6.3.2)

72

iii) Internal ionization or partial discharge test

b) Special Acceptance tests:i) Thermal stability test (IEC clause 7.2.2)

c) Routine tests:Measurement of reference voltage

i) Residual voltage test of arrester unitii) Internal ionization or partial discharge testiii) Sealing testiv) Verticality check on completely assembled surge arresters as a sample test on each lot if

applicable.

d) Type tests: Following shall be type test As per IS 3070 (Part 3)-/IEC;60094 or its latestamendment


a) Lightning Impulse voltage testb) Power Frequency (Dry & Wet)

2. Residual Voltage Test

a) Steep current impulse residual voltage testb) Lightning Impulse Residual Voltage Test

3. Long duration current impulse withstand test

4. High current impulse operating duty test

5. Power frequency voltage Vs. Time characteristics

6. Accelerated Ageing test

7. Artificial pollution test (for porcelain housing)

8. Partial discharge test

9. Visual Examination (for porcelain housing)

10. a) Temperature cycle test (for porcelain housing)

11. Mechanical Failing Load test

(Bending Strength test)

73

12. Uniformity of Zinc coating, Mass of zinc coating

13. Time versus current curve (for disconnector)

14. Weather ageing test (for polymer housing)

3.7.2. The maximum residual voltages corresponding to nominal discharge current of 5 kA for steep current,impulse residual voltage test, lightning impulse protection level and switching impulse level shall generallyconform to Annex-K of IEC-99-4.

3.7.3. The contractor shall furnish the copies of the type tests and the characteristics curves between theresidual voltage and nominal discharge current of the offered surge arrestor and power frequencyvoltage v/s time characteristic of the surge arrestor subsequent to impulse energy consumptionas per clause 6.6.7 of IS:3070 (Part-3) offered alongwith the GTP.

3.7.4. The surge arrestor housing shall also be type tested and shall be subjected to routine and acceptance testsin accordance with IS: 5621

3.7.5. GALVANIZATION TESTAll Ferrous parts exposed to atmospheric condition shall have passed the type tests and be subjected toroutine and acceptance tests in accordance with IS:2633 & IS 6745.

3.7.6. TEST ON SURGE ARRESTOR DISCONNECTORSThe test shall be performed on surge arrestors which are fitted with arrestor disconnector or on thedisconnector assembly alone if its design is such as to be un-affected by the heating of adjacent parts ofthe arrestor in its normally installed portion in accordance with IS:3070 (Part-3)

3.8. NAME PLATE


- Rated Voltage






- Name of Client-


3.9. DRAWINGS AND INSTRUCTION MANUALS

The successful bidder shall furnish to the purchaser the following drawings and literature for approval:

74

(i) Outline dimensional drawings of Surge Arrestor and all accessories.

(ii) Assembly drawings and weights of main component parts.

(iii) Drawings of terminal clamps.

(iv) Arrangement of earthing lead.

(v) Minimum air clearance to be maintained of line components to ground.

(vi) Name plate

(vii) Instructions manual

(viii) Drawing showing details of pressure relief valve

(ix) Volt-time characteristics of surge arrestors

(x) Detailed dimensional drawing of porcelain housing/Silicon polymeric i.e. internal diameter, externaldiameter, thickness, height, profile, creepage distance, dry arcing distance etc.



System Parameters

i) Nominal system voltage 11kV

ii) Highest system voltage 12 kV

iii) System earthing Solidly earthed system

iv) Frequency (Hz) 50

vii) Lightning Impulse withstand 75 Voltage (kVP)

viii) Power frequency withstand 28 Voltage (kV rms)

vii) Arrestor duty-- Connection to system Phase to earth-- Type of equipment to be protected 11 kV transformers & switchgear

3.10.2. Surge Arrestorsi) Type Gapless Metal oxide outdoor

ii) Arrestor rating (kV rms) 9

iii) Continuous Operating voltage (kV rms) 7.65v) Nominal Discharge Current 5 Rating (kA) (8x20 micro impulse shape)

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v) Long Duration discharge class Distribution class

vi) Maximum residual voltage (kV peak)a) at 5 kA 27

vii) Partial discharge at 1.05 COV not greater than 50 (PC)

viii) High current impulse withstand voltage at 5 kA (kVp) 65

3.11. INSULATOR HOUSING

i) Power frequency withstand test voltage (Wet) (kV rms) 28ii) Lightning impulse withstand/tests voltage (kVP) 75iii) Creepage distance not less than (mm) 300

3.12. GALVANISATION

i) Fabricated Steel Aticlesa) 5 mm thick cover 610 g/m2

b) Under 5 mm but not less than 2 mm thickness 460 g/m2

c) Under 2 mm but not less than 1.2 mm thickness 340 g/m2

ii) CastingsGrey Iron, malleable iron 610 g/m2

iii) Threaded works other than tubes & tube fittingsa) Under 10 mm dia 270 g/m2

b) 10 mm dia & above 300 g/m2

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7. 11KV & 33 KV Metering Units

1 SCOPE:

This specification covers design, engineering, manufacture, assembly, stage testing, inspection,testing before dispatch, supply and delivery of 11KV & 33KV CT PT Combined Metering unit Sets of class ofaccuracy 0.5 for 11 KV MU, 0.2 for 33 KV MU as per the particulars given in the schedule attached.

2 STANDARD: Except where modified by this specification the component parts of the equipment shallcomply with the following ISS available ( the latest versions).

Current T Transformers :IS 2705/1992

Potential Transformers :IS 3156/1992HV Porce lain Bushing :IS 2099/1986

Oil :IS 335/1983Galvanization :IS 2633

Primary Terminals :IS 10601Oil :IS 335

3 TYPE FOR 11 KV: The metering transformer equipment should be of pole mounting type for outdoor use.They are to be used in 11KV Three Phase with solidly earthed neutral and suitable for 3 Phase 4 Wire 50cycles network. The equipment is required for operation of HT Trivector Meters and should be oil cooled.The CTPT sets shall have the following ratings:

i) Rated Voltage: 11 KVii) Highest system voltage: 12 KViii) Insulation level: 12 KViv) Standard Impulse withstand voltage: 75 KV Peakv) One minute power frequency withstand Voltage

Primary 28 KV

Secondary 3 KV

vi) Short time thermal current and its duration6 KA for 1 sec for CT ratio below 50/5 A1 3 .1 K A for 1 sec for CT ratio = 50/5 A(including 50/5 A)

vii) Class of Accuracy: 0.5 (Negative (-ve) errors will not be acceptable.)

viii) Rated burden per phaseFor CTs: 15 VAFor PTs: 50 VA

ix) Frequency: 50 HZx) Maximum attainable winding temperature =80 deg Cxi) Minimum Phase to Phase distance=255 mmxii) Shortest distance between metal part & earth = 190mmxiii) Creepage distance of HV bushing 300mm (Min)xiv) Gauge of MS Tank Min 5mm for top & bottom cover & 3.15 mm all other sides

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xv) Entire tank shall be hot dip galvanized.xvi) Bi-metallic terminal connector with a nut, plane washer, spring washer & Check nut

suitable for aluminum conductor required for different rating of metering units. Six nos. to beprovided with each metering units.

4. TYPE FOR 33 KV: The metering transformer equipment should be of pole mounting type for outdoor use. They are tobe used in 33 kV Three Phase with solidly earthed neutral and suitable for 3 Phase 4 Wire 50 cycles network. Theequipment is required for operation of HT Trivector Meters and should be oil cooled.

The CTPT sets shall have the following ratings.i) Rated Voltage: 33 KV

ii) Highest system voltage: 36 KViii) Insulation level: 36 KViv) Standard Impulse withstand voltage: 170 KV peakv) One minute power frequency withstand Voltage

a. Primary : 70 KV

b. Secondary : 3 KVvi) Short time thermal current and its duration

6 KA for 1 sec for CT ratio below 50/5 A13.1 KA for 1 sec for CT ratio for > 50/5 A (including 50/5A)

vii) Class of Accuracy: 0.2 (Negative (-ve) errors will not be acceptable.)viii). Rated burden per Phase

1. For CTs: 5 VA up to 50/5 A & 10 VA for => 50/5 A2. For PTs: 50 VA

ix). Frequency: 50 HZ

x). Maximum attainable winding temperature =80 deg Cxi). Minimum Phase to Phase distance=430 mm

xii). Shortest distance between metal part & earth = 380 mmxiii). Creepage distance of HV bushing 900mm (Min)

xiv).Thickness of MS Tank Min 5mm for top cover & 3.15 mm bottom & all other side.xv). Entire tank shall be hot dip galvanized.

xvi). Bi-metallic terminal connector with a nut, plane washer, spring washer & check nut suitable for aluminium conductorrequired for different rating of metering units. Six nos to be provided with each metering units.

5. DESIGN:

a) The equipment shall be designed to ensure satisfactory operation under all conditions of service to facilitate easyinspection, cleaning and repairs.

b) The design shall incorporate every reasonable precaution and provisions for safety ofall those concerned in the operation and maintenance of the equipment.A pressure relief valve shall be invariably provided to the CT PT set. IT shall be providedat the top cover of the tank.

c) All outdoor apparatus shall be so designed that water cannot collect at any point and enter the CT/PT set. The topcover of the tank, secondary terminal cover, inspection chamber cover plate is suitable bent at the edges (at least25mm bent) so that the gaskets are not exposed to moisture.

d) All connections and terminals shall be of sufficient size for carrying the specified currents continuously without undueheating.

e) All bolts, nuts, washers in contact with non-ferrous parts shall be of brass.

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f) All ferrous parts including bolts & nuts liable to corrosion, forming integral part of the equipment shall be smoothly andcontinuously hot dip galvanized.

g) The secondary terminal box, inspection cover and oil gauge shall be arranged with MU.

h) The core shall be high grade non-ageing electrical silicon laminated steel or of better grade of low hysteric loss and highpermeability to ensure high accuracy, at both normal and over current/voltage.

i) All winding shall be of insulated high grade Electrolytic copper wire and the manufacturing of the units shall be donecompletely closed and air-conditioned room otherwise fibre glass insulation sleeves are to be provided for primarywinding. Details of winding and core shall be furnished.

j) The CTPT set should have Three CTs and Three PTs with star/star connection.

6. SEALING:

Sealing bolts for sealing at 4 points on the secondary terminal box (both inner & outer door),inspection cover, the top cover of the tank shall be provided. This may be made by providing a hole on tailof corner bolts ofadequate size to pass the sealing wire or above13 SWG.

7. FLUCTUATION IN VOLTAGE AND FREQUENCY:

For continuous operation, entire equipment shall be subjected to variation of voltage up to plus 20 minus 30 frequency ofplus or minus 5 percent.

8. INSTRUMENT TRANSFORMERS:

a) The voltage and current transformers shall have normal continuous rating as per the schedule of requirement.

b) The voltage transformer shall be so designed that the increased magnetizing currents due to anypersisting over voltage, does not produce injurious over heating Phase barriers shall be provided.

c) The peak value of the rated dynamic current shall not be less than 2.5 times the rated short time thermal currentunless stated otherwise. (4.62 of ISS: 2705/Part-I of 1992, latest version).

d) Modified polyester enamel copper wire is to be used for winding and it shall conform toIS-4800/Part-V (latest version).

e) The terminals of the instrument transformer shall be clearly marked by distinctive letters asstated in Annex “C” of ISS: 3156/Part.I/1992 (latest version) for voltage transformer and Annex “C” of IS-2705/Part.I/1992 (latest version) for current transformers.

f) The winding shall be neatly laid and anchored.

g) The metering set tank and other metal parts shall be galvanized both inside & outside as per latest ISapplicable.

9. INCOMING SIDE:

TERMINALS: Brass rods 12mm dia for Primary and 6 mm dia for secondary keeping current density of 1.6Aper sq. mm size of rod may be designed by manufacturer for given CT/PT.Bushing for outgoing side of CT/PT set :The porcelain portion of HT bushings shall be of standard make and conform to IS-2099/1996.

The dimensions of the bushings shall conform t o I S - 33 4 7 /Part.III/19 The minimum phase-to-phase clearance shall be

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as per IS.

The tests as per IS-2099/1962 shall be conducted on the transformer bushings as detailed below:

a) Dry flash over voltage.b) Wet flashover voltage.c) Dry 1 Min. withstand volt.d) Impulse withstand voltage (1.2/50 Micro Seconds –ve wave)e) Manufacturer‟s test certification may be furnished for every lot of offer.

The bushings shall be of reputed manufacturers like M/s. Jayashree Insulators, M/s. WS Industries, M/s.BHEL,M/s. Allied Ceramics, M/s. India Potteries and M/s. IEC which are having complete testing facilities.

The bushing stems shall be provided with suitable bimetallic connectors so as to connect the jumperwithout disturbing the bushing stem.

f) The bush rod stem length should be at least 40 mm and 3 nuts with 2 flat washers of brass material should beprovided with each bush rod.

10. STEEL TANK:

The oil filled container incorporating the voltage transformers and current transformers should be fitted with incomingand outgoing primary terminals and secondary terminal box. The secondary terminal box shall be arranged on sides. Thegeneral arrangement drawing with 3 bushing on the incoming side and 3 bushings on the outgoing side shall be submittedalong with tender.The tank shall be built with a plate of 5 mm thick top and 3.15 mm sides and bottom end with all fittings shall be capable ofwithstanding without leakage or distortion at the standard test pressure. All joints of the tank and fittings shall be hot oil tightand no leakage should occur during service. Both side of the joint should have continuous welding.

a) It shall be provided with an oil gauge as shown. The oil gauge glass shall be fixed to the side of the raised wall ofthe inspection box.

b) The tank shall be provided with necessary lifting lugs. Tank including top cover shall be hot deep Galvanized.

c) The secondary terminal box cover, tank cover and inspection cover and other vertical joints where gasketsare used shall be suitably bent at least 25 mm bent with necessary sealing arrangement with sealing bolts atall corners and bolts should be at least 10 mm diameter GI bolts spaced maximum 70 mm apart. This is tosafeguard against seepage of water into tank in case of damaged gasket.

d) The 6 mm gaskets shall be dovetailed without joints to prevent moisture entry. In case of dovetailed joint,they shall not be more than two. The gaskets shall be of good quality Neoprene or superior qualityrubberized gasket.

e) EARTHING: Two earthing terminals shall be adequate size protected against corrosion and metallicallyclean and identified by means of the sign marked in a legible and indelible manner on or adjacent to theterminals.

1 All bolts should be provided with 2 flat washers and a spring washer with a nut.

2 Conservator should not be provided for these CTPT sets.

3 The Secondary terminal box incoming hole should be 32 mm diameter and at a suitable height from bottom to avoidreplacement/ modification of secondary wires pipe when CTPT set is replaced. The secondary terminals size shouldbe 6 mm diameter, 25 mm stem length, 2 flat washers with 3 nuts of brass material should be provided. Theterminals should be provided at least 70 mm height from incoming hole and clearances shall be as per IS to avoidshorting terminals due to secondary wires pipe.

f) Secondary chamber shall have double door (inner & outer) with suitable arrangement for sealing of

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both the doors. The inner door shall be of transparent Polycarbonate so that secondary terminal connectionscan be viewed without breaking the inner door seals.

g) The following details of equipment shall be engraved on tank with at least 10 mm letters.1. Make

2. Ratio

3. Class of accuracy

4.Serial No:

5. Month & year of manufacturing

6 . Property of Employer.

66 months guarantee embossed plate shall be welded opposite side of name plate.

11. MOUNTING ARRANGEMENT:

The under base of all CTPT sets shall be provided with two 75x40mm GI channels and foundation dimensions shall besuitable placing with tank base uniform for all sets with only ±2 mm tolerance, to avoid modification of structure / plinth,whenever CTPT set is replaced

12. OIL: The insulation oil used in the tank shall comply with the requirements specified in latest relevant IS: 335/93and as per Annexure-C.

13. GUARANTEED TECHNICAL PARTICULARS:The Technical Particulars as specified in IS shall be guaranteed. Every tenderer should furnish the particulars required andguarantee the values so furnished for the supplies.

14. TESTS:

TYPE TESTS: The equipment offered shall be fully type tested from recognized standard govt. national laboratory by thebidder as per the relevant certificates shall be furnished. The bidders also furnish type test certificates for bushings and oilalong with the Bid. The type test certificates shall be not older than (5) years.

TYPE TESTS FOR CTs:

a) Verification of terminal marking and polarityb) Short time current Test.c) Temperature rise test.d) Lightning Impulse teste) High Voltage Power frequency wet withstand voltage test.f) Determination of errors or other characteristics according to the requirements of the appropriate

designation or accuracy class.

TYPE TESTS FOR PTs:

a) Verification of terminal marking and polarity.b) High voltage Power frequency wet withstand voltage test.c) Power frequency dry withstand tests on Primary winding. Power frequency dry

withstand test on Secondary winding.d) Determination of errors according to the requirements of the appropriate accuracy class.e) Temperature rise test.f) Impulse Voltage test.g) Lightning Impulse test

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TYPE TESTS FOR TRANSFORMER BUSHINGS:

i) Dry flash over voltage.ii) Wet flash over voltage.iii) Dry 1 Minute withstand voltage.iv) Impulse withstand voltage (1.2/50 Micro Seconds –ve wave)

ACCEPTANCE AND ROUTINE TESTS:

The following shall be conducted as per IS: 3156 (Latest version).

i) Verification of Terminal marking and polarity.ii) Power frequency/ dry withstand tests on primary windings.iii) Power frequency dry withstand tests on secondary windings.iv) Determination of errors according to the requirements of the appropriate accuracy class.v) Temperature rise test.

vi) Air pressure test on empty tank of M U opened for verification test (One for every lot offered for pre-dispatch inspection)

vii) All acceptance and routine tests as stipulated in the relevant standards shall be carried out by the manufacturer inpresence of Employer representatives.

15. DRAWINGS AND LEAFLETS (along with tender):

Two sets of drawings showing clearly the general arrangements, sectional views, fitting details, electrical connections,foundation details, overall dimensions and design features of each component part should accompany the tender. Thecontractor has to submit clear & detail drawing with description how he will arrange the double door system in secondarychamber with sealing. Technical leaflets giving the operating instructions should also be furnished along with tender.Literature and drawings are to be sent along with each equipment while dispatching, after approval of Project Manager.

16. DEVIATIONS:The deviations between these CTPT sets and NABL approved Standard Lab (CPRI, ERDA, etc.,) type tested CTPT setalong with detailed reasons for deviations if any shall be submitted along with tender.

17. TOLERANCES:Unless otherwise specified herein the test value of the transformers supplied should be within the tolerance permitted inthe IS on the guarantee values.

18. SEALING OF CTPT SETS AFTER TESTING AND INDIVIDUAL TEST REPORTS:

After witnessing testing on sample quantity and physical inspection of all offered CTPT sets, the purchaser‟srepresentative will provide numbered plastic seal bits to two opposite corners of tank, Secondary Chamber and inspectioncover of all offered CTPT sets, for delivery of correct inspected materials only. The manufacturer has to provide testreport duly mentioning all test results, seal bit numbers and name & address of Employer representative after inspectionis over. The seal bit numbers shall also be mentioned in the test reports signed by Employer representativesubmitted for delivery instructions.

19. INSPECTION AND TESTING OF TRANSFORMER OIL:To ascertain the quality of transformer oil the manufacturer’s test report shouldbe submitted at thetime of inspection. Arrangements should also be made for testing the transformer oil, after taking outthe samples from the manufactured CTPT sets and tested in the presence of Employer representative (or) if desired, in anindependent laboratory manufactured CTPT sets and tested in the presence of Employer representative (or) if desired, in anindependent laboratory.

20. DEPARTURE FROM SPECIFICATION:If the tenderer wishes to depart from this specification in any respect, he shall draw the attention to such points ofdeparture explaining fully the reasons therefore. Unless this is done the requirements of this specification will bedeemed to have been accepted in every respect.

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21. NAME PLATE:The Purchase order No. and Date of purchase order, the words “PROPERTY OF EMPLOYER NAME”. The name plate shallbe non-detachable type & fixed with rivets, not with bolts & nuts. The name plate should bear year & month of manufacture& other data as per IS. Space should be provided to punch the date of installation by user group.

22. WARRANTY:The manufacturer will warrant for the satisfactory functioning of the material / equipment as per specification for aminimum period of 66 months from the date of dispatch of the material / equipment in good condition indicating GPcovering date upto --------------

23. The tenderer shall indicate the source of all materials. He shall also indicate the name of the manufacturer and make ofconductor, Transformer oil Electrical Steel Laminations, Construction Steel etc.

24. FITTINGS:The following standard fittings shall be provided.a) Rating and terminal marking plates non detachable -1no.b) Earthing terminals with bolt, nuts & washers for connecting earth wire - 2Nos.c) Lifting lugs -4Nos.for main tank and 2Nos. for top cover.d) Pressure relief valve. – 1 no.e) Bimetallic terminal connectors on the HV bushings – 6 Nos.f) HV bushings Outdoor – 6 Nos.g) Secondary terminals bushings – 10 Nosh) Base channels 75 x 40 mm.i) 66 months guarantee embossed plate welded to tank opposite side of name plate.j) Tank and over all dimensions.k) Weight content of a) core b) windings c) tank & fittings d) weight/qty. of oil e) over all weight.

SCHEDULE OF MATERIALS:

Sl. No. Name of the Materials

1 11KV Metering Unit (CTR = 10/5A)






83













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8. Energy Meter

1 SCOPE:This specification covers design, engineering, manufacture, assembly, stage testing, inspection, testing

before dispatch, supply and delivery of 11KV & 33KV CT PT Combined Metering unit Sets of class of accuracy

0.5 for11KV MU, 0.5 for33KV MU as per the particulars given in the schedule attached.

2 STANDARD: Except where modified by this specification the component parts of the

equipment shall comply with the following ISS available (the latest versions).

CurrentT Transformers : IS 2705/1992

Potential Transformers : IS 3156/1992

HV PorcelainBushing : IS 2099/1986

Oil : IS 335/1983Galvanization : IS 2633

Primary Terminals : IS 10601:

3 TYPE FOR 11KV: The metering transformer equipment should be of pole mounting type for outdoor use. They

are to be used in 11KV Three Phase with solidly earthed neutral and suitable for 3Phase 4Wire 50 cycles network. The

equipment is required for operation of HT Trivector Meters and should be oil cooled. The CTPT sets shall have the

following ratings:

i) Rated Voltage: 11KV

ii) Highest system voltage: 12KV

iii) Insulation level: 12KV

iv) Standard Impulse withstandvoltage:75KVPeak

v) One minute power frequency withstand Voltage

Primary 28KVSecondary 3KV

vi) Short time thermal current and its duration 6KA for 1 sec for CT ratio below 50/5A, 13.1KA for1 sec for CT ratio

above 50/5A (including 50/5A)

vii) Class of Accuracy: 0.5(Negative (-ve) errors will not be acceptable.)

viii)Rated burden per phase

For CTs : 5VA (at 0.8 lagging pf)For PTs: 30VA (at 0.8 lagging pf)

ix) Frequency: 50HZ

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x) Maximum attainable winding temperature =80 deg C

xi) Minimum Phase to Phase distance=255 mm

xii) Shortest distance between metal part & earth= 190mm

xiii)Creepage distance of HV bushing =300mm (Min)

xiv) Gauge of MS Tank Min 5mm for top & bottom cover & 3.15mm all other sides

xv) Entire tank shall be hot dip galvanized.

xvi) Bi-metallic terminal connector with a nut, plane washer, spring washer & Check nut suitable for aluminum conductorrequired for different rating of metering units. Six nos. to be provided with each metering units.

4 DESIGN :

a) The equipment shall be designed to ensure satisfactory operation under all conditions of service tofacilitate easy inspection, cleaning and repairs.

b) The design shall incorporate every reasonable precaution and provisions for safety of all those concernedin the operation and maintenance of the equipment. A pressure relief valve shall be invariably provided to theCT PT set. It shall be provided at the top cover of the tank.

c) All outdoor apparatus shall be so designed that water cannot collect at any point and enter the CT/PT set. Thetop cover of the tank, secondary terminal cover, inspection chamber cover plate is suitable bent at the edges (atleast 25mm bent) so that the gaskets are not exposed to moisture.

d) No inspection cover at any side of the CTPT shall be provided.

e) All connections and terminals shall be of sufficient size for carrying the specified currents continuously withoutundue heating.

f) The CTPT sets shall be hermetically sealed type (should not communicate with atmospheric air) inconstruction without any oil conservator. The workmanship should be of the highest standard.

g) All bolts, nuts, washers in contact with non-ferrous parts shall be of brass.

h) All ferrous parts including bolts & nuts liable to corrosion, forming integral part of the equipment shall besmoothly and continuously hot dip galvanized.

i) The secondary terminal box and oil gauge shall be arranged with MU.

j) The core shall be high grade non-ageing electrical silicon laminated steel or of better grade of low hysteric lossand high permeability to ensure high accuracy, at both normal and over current / voltage.

k) All winding shall be of insulated high grade Electrolytic copper wire and the manufacturing of the units shallbe done completely closed and air-conditioned room otherwise fibre glass insulation sleeves are to be providedfor primary winding. Details of winding and core shall be furnished.

5 SEALING :

Sealing arrangement for sealing on the secondary terminal box (both inner & outer door) and the top cover of thetank shall be provided. This may be made by providing a hole on tail of corner bolts of adequate size to pass thesealing wire or above 13 SWG.

6 FLUCTUATION IN VOLTAGE AND FREQUENCY :For continuous operation, entire equipment shall be subjected to variation of voltage up to plus 20 minus 30

frequency of plus or minus 5 percent.

7 INSTRUMENT TRANSFORMERS:a) The voltage and current transformers shall have normal continuous rating as per the schedule of

requirement.

86

b) The voltage transformer shall be so designed that the increased magnetizing currents due to any

persisting over voltage, does not produce injurious overheating Phase barriers shall be provided.

c) The peak value of the rated dynamic current shall not be less than 2.5 times the rated short time

thermal current unless stated otherwise. (4.62 of ISS: 2705/Part-I of 1992, latest version).

d) Modified polyester enamel copper wire is to be used for winding and it shall conform to IS-4800/Part-V

(latest version).

e) The terminals of the instrument transformer shall be clearly marked by distinctive letters as stated in

Annex― C of ISS: 3156/Part. I/1992 (latest version)for voltage transformer and Annex―C ‖of IS-

2705/Part. I/1992 (latest version) for current transformers.

f) The winding shall be neatly laid and anchored.

g) The metering set tank and other metal parts shall be galvanized both inside & outside as per latest IS

applicable.

8 INCOMING SIDE:TERMINALS: Brass rods 12mm dia for Primary and 6mm dia for secondary.

Bushing for outgoing side of CT/PT set:

The porcelain portion of HT bushings shall be of standard make and conform to IS- 2099/1996.

The dimensions of the bushings shall conform to IS -3347/Part. III/19Theminimumphase-to-phaseclearance shall be as perIS.

The tests as per IS-2099/1962 shall be conducted on the transformer bushings as detailed

below:

a) Dry flash overvoltage.

b) Wet flashover voltage.

c) Dry 1 Min. withstand volt.

d) Impulse withstand voltage (1.2/50 Micro Seconds –ve wave)

e) Manufacturer’s test certification may be furnished for every lot of offer.

The bushings shall be of reputed manufacturers like M/s. Jayashree Insulators, M/s. WS

Industries, M/s. BHEL, M/s. Allied Ceramics, M/s. India Potteries and M/s. IEC which are

having complete testing facilities.

The bushing stems shall be provided with suitable bimetallic connectors so as to connect the

jumper without disturbing the bushing stem.

f) The bush rod stem length should be at least 40mm and 3 nuts with 2flat washers of brass material should be

provided with each bush rod.

9. CORE:

9.1 CORE MATERILAS:

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Non aging oxide film coated fresh suitable Mu-metal or Mu-metal plus CRGO toroidal cores for CT. For lamination of PT

first quality laser grade CRGO shall be used as core material. All the stresses developed due to cuttings, punching etc.

shall be relieved by suitable stress relieving process.

9.2 CORE CONSTRUCTION AND DESIGN:Core is supporting steel and insulation shall be such that harmful changes in electrical and physicalproperties shall not occur during the life time of the CTPT unit.

Core winding shall be strongly braced so that it shall not get displaced in operation due to shrinkage on shortcircuit forces. Core assembly shall be rigidly clamped with M.S. Channel and mounted to the tank.

9.3 CORE OF PT:The core of PT shall be effectively earthed by copper braided flexible wire of minimum area of 40 mm2 cross-section. The core shall be rigidly branched with insulated bolts an the assembly shall be rigidly clamped withMS Channels and mounted on the tank.

9.4 CORE OF CT:The tenderer shall provide toroidal core only. It should be same as given in type tested unit. Core / Windingassembly of CT shall be rigidly mounted in the tank.

10. WINDING:It shall be of electrolytic grade copper conductor with super enameled Insulation, conforming to relevant ISS. Thewinding design and contraction shall be such that it shall withstand impulse voltage. The details as per GuaranteedTechnical Particulars shall be provided. The winding shall be preferable in two sections.

11. CT WINDING :It shall be of electrolytic grate copper conductor with DPC/DCC and super enameled insulation conforming relevantISS. The winding design and construction shall be such that it shall withstand impulse voltage and short circuitcurrents. The winding shall be provided with rigid insulating supporting hylum sheets of minimum 5 mmthickness on both the sides duly tightened by insulating fasteners only and by cotton cord etc.

a) Each coil shall be wound of paper insulated, continuously, smooth high grade, electric copperconductor.

b) The materials used in the insulation and assembly of the winding shall be in-soluble, non-catalytic andchemically inactive in the transformer oil.

c) Winding assembling shall be dried in vacuum thoroughly shrunk to final alignment and vacuumimpregnated with tested transformer oil.

d) Design arrangement, insulated and assembly of the winding on the core shall be so as to ensure uniformdistribution of voltage amongst all coils.

12. BUSHING:a) Brown glazed HV bushing of approved make shall mounted as stated in 4(e) of Annexure-I on top cover of

tank. The list of approved suppliers for Porcelain insulators may be obtained from this office. The hollowporcelain bushings shall be confirming to IS-5621. The metal parts of the bushings shall be tinned copperwith minimum tinning with 50 micron with spring washer and plain washer (minimum 2.0 mm thickelectroplated) with 3 (three) nos. nuts, one lock nut and two nuts for terminal connections

b) Bushing clamping and accessories together with the connected bolts/studs shall be hot dip galvanized.However, nuts and washers shall be SS-304.

c) Arcing horn should be avoided.

88

d) Suitable bird guard will be required for all HT bushings

The tests as per IS-2099/1962 shall be conducted on the transformer bushings as detailed below :

a) Dry flash over voltage.

b) Wet flashover voltage.

c) Dry 1 Min. withstand volt.

d) Impulse withstand voltage (1.2/50 Micro Seconds –ve wave).

e) Manufacturer‟s test certification may be furnished for every lot of offer.

The bushings shall be of reputed manufacturers like M/s. Jayashree Insulators, M/s. WSIndustries, M/s. BHEL, M/s. Allied Ceramics, M/s. India Potteries and M/s. IEC which are havingcomplete testing facilities.

13. STEEL TANK :

The tank shall be fabricated from fresh MS Sheet of 5mm, thickness for top cover, flange and bottom of the tank andof 3.0mm thickness for side walls so as to withstand pressure built in during the expansion of oil duringtemperature rise or forces generated during short circuit. The expose fabricated tank with cover and other ferrousfittings shall be thoroughly cleaned, scrapped process and hot dip galvanized as per relevant IS-2629. All nuts, bolts,washers, screws, etc. exposed to the atmosphere shall be of 304 grade of stainless steel.

The curb of the tank shall be minimum 50mm wide. The top cover shall have slope of minimum 10 degree to drainoff water in rainy season. The oil resistant gasket of neoprene rubber or nitral or synthetic rubberized corkof minimum 8mm thickness shall be provided. Adequate number of SS-304 grade bolts of M12 x 50mm (length)size bolts at maximum 115mm (with tolerance of mm) C/C apart with 2 mm thick washer of 304 grade SS shallbe provided. Four numbers of lifting lugs of 5mm thickness shall be provided on tank sides and two nos. on topcover. The top cover should be fabricated in such a way that nowhere the top cover gasket is exposed to air.

Suitable PRV are to be placed on the top cover of the tank to prevent explosion

14. TERMINAL BOXThe terminal box shall be closed box type, water/vermin proof with tinned copper terminals of minimum 6mmdia x 35mm with electroplated spring washers and three numbers nuts. The terminal marking and polaritymarking shall be done by etched aluminum square plated duly fixed in irremovable manner. The terminal boxshall have cable entry hole to accommodate metallic gland (approx of 1.1/4” size) suitable to termination of 10core, 2.5 Sq. mm PVC insulated steel armored cable. The terminal box covers shall have the provision of sealing theterminal box for which minimum four nos. of corner bolts to be fixed on the flange of the box shall be providedwith adequate hole on the bottom for sealing purpose. The terminal box with the cover closed and cable inposition must have degree of protection conforming to IP-54. The minimum projection of the box shall be 70mm.

The Serial number, ratio, and date of dispatch shall have to be ENGRAVED on side (opposite to secondary terminalbox), of tank with letter of suitable depth and 25mm height filled with RED color.

The fabrication of the CTPT set tank shall be such that there should not be any oil leakage from welded positions.The four numbers corner bolts of top cover shall have suitable hole for inserting sealing wire.

14.1 Secondary chamber shall have double door (inner & outer) with suitable arrangement for sealing ofboth the doors. The inner door shall be of transparent Polycarbonate so that secondaryterminal connections can be viewed without breaking the inner door seals.

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14.2 The following details of equipment shall be engraved on tank with at least 10 mm letters.

1. Make

2. Ratio

3. Class of accuracy

4. Serial No:

5. Month & year of manufacturing

6. Property of Employer.

66 months guarantee embossed plate shall be welded opposite side of name plate.

15. MOUNTING ARRANGEMENT :

The under base of all CTPT sets shall be provided with two nos of 150x75x6 mm GI channels and foundationdimensions shall be suitably placed with tank base uniform for all sets with only ±2 mm tolerance, to avoidmodification of structure / plinth, whenever CTPT set is replaced.

16. OIL :The transformer oil to be supplied in the CTPT tank shall be new oil conforming to requirements as stated inAnnexure-II when tested according to IS-335/1983

The current transformer shall be so constructed as to ensure that the oil does not flow or leak out even whenthe current transformer is used continuously at the maximum allowable temperature; similarly the potentialtransformer shall be so constructed as to ensure that the oil does not flow or leak out

Oil should be filled up to the top of HT side bushing, hence necessary provision should be made forexpansion of oil due to rise in temperature

17. GUARANTEED TECHNICAL PARTICULARS :

The Technical Particulars as specified in IS shall be guaranteed. Every tenderer should furnish the particularsrequired and guarantee the values so furnished for the supplies.

18. CABLEDETAILS:

The terminal box shall have cable entry hole of size 38mm dia. with 1.1/4 inch double compression flame proof metalcable glands to avoid cutting of cable sheath. The terminal box shall have provision to seal the terminal box.

19. CLEARANCE:The minimum air clearance for HV shall be as per IS-3347.

20. TESTING & INSPECTION:

20.1 QUALIFICATION:

The tenderer shall have to furnish to following test certificates and documents:

i. All type tests certificates as listed under Annexure-III carried out on ONE single sample unit and tests must notbe carried out more than five years prior to the date of submission of the tender offer. The above testshould be carried out in any Govt. approved Test Lab as indicated above.

ii. The tenderer shall also submit one type test certificate for the test of “Instrument Security Factor” as per theCl. No. 7.1.2 of IS-2705 (Part-II). The value of ISF must be 2.5 or less than 2.5 and the test must havebeen conducted at any Govt. Testing Lab not prior to more than 3 years from the date of submission of the

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offer.

iii. The copy / proof of bill / in voice of purchase of core material.

iv. The copy of BH curve for the core material intended to be used in regular supply of CTPT units.

If above test certificates are not submitted the offer will not be considered as “Qualified”.

20.2 TYPE TEST CERTIFICATE:On the strength of above qualification, LOI will be placed if offer passed in on other requirements. However,before commencement of bulk supply, the supplier has to submit Test Certificates for all the Type Tests asprescribed under Annexure-III for CTPT sets with ratio as specified.

20.2.1 The APDCL also reserves the right to carry out all or any type tests on any CTPT set from the lot offered forinspection by the firm at CPRI / ERDA or Govt. Recognized Lab. in presence of APDCL officers andrepresentative of firm at APDCL’s cost. Any decision based on this testing shall be applied to the full rderedquantity. However, if the unit fails in test, then the test charges shall have to be borne by the supplier.

20.3 ACCEPTANCETESTS:The tests shall be carried out at manufacturer’s work as “Acceptance Tests” on all CTPT sets offered forinspections as per applicable is of individual units and this specification as per Annexure - IV.

20.4 ROUTINE TESTS:The firm shall carry out the routine tests on each CTPT set being offered for inspection and submit the routinetest certificate to the inspector deputed for inspection of CTPT sets and acceptance of the lot. Routine tests shallbe carried out as per Annexure-V.

21. GUARANTEE:The combined CTPT set offered shall have guarantee for good design, materials and workmanship. The defectiveunits shall have to be repaired / replaced free of cost if reported 66 months of their receipt at site or 60months from the date of commissioning of equipments whichever is earlier.

The firm shall be responsible for proper performance of the equipment for 66 months of their receipt at site or 60months after commissioning whichever is earlier.

Reported failed units under guarantee period as above shall be repaired / replaced as early as possible. Inany case, it should be repaired / replaced within 30 days. The failed units are to be collected by the supplierfrom our field offices within 15 days of reporting. If immediate arrangement for collection of failed unit is notcollected and if the units are not repaired within two months time, the APDCL will deduct full cost of CTPT unitfrom the security amount. All the suppliers have to give 10% Performance Bank Guarantee in advance as securitydeposit.

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ANNEXURE – III

Schedule of Type Test for CT :

1. Verification of terminal marking and polarity.

2. High voltage power frequency tests on primary windings.

3. High voltage power frequency tests on secondary windings.

4. Over voltage inter turn test.

5. Determination of error according to the requirement of appropriate accuracy class.

6. Short time current test.

7. Impulse voltage test.

8. Temperature Rise Test.

9. Instrument Security Factor Test on Both phase of the CT as per Cl. No.7.1.2 of Is-2705 (Part-II).

10. High Voltage Power-frequency Wet withstand voltage test as per Cl. No.9.9 of IS-2705 (Part-I).

Schedule of Type Test for P.T :


2. Power frequency dry withstand test on primary winding.

3. Power frequency dry withstand test on secondary winding.

4. Determination of errors according to the requirement of the appropriate accuracy class.

5. Temperature rise test.

6. Impulse voltage test for voltage transformer for service in electricity exposed installation.

7. High Voltage Power-frequency Wet withstand voltage test as per Cl. No.9.7 of IS-3156 (Part-I).

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ANNEXURE – IV

Schedule of Acceptance Test for CT :




4. Over voltage inter-turn test.



Schedule of Acceptance Test for P.T. :





ANNEXURE – V

Schedule of Routine Test for CT :




4. Over voltage inter-turn test.



Schedule of Routine Test for P.T. :





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22. DRAWINGS AND LEAFLETS (along with tender):

Two sets of drawings showing clearly the general arrangements, sectional views, fitting details, electrical

connections, foundation details, overall dimensions and design features of each component part should accompany

the tender. The contractor has to submit clear & detail drawing with description how he will arrange the double

door system in secondary chamber with sealing. Technical leaflets giving the operating instructions should also

be furnished along with tender. Literature and drawings are to be sent along with each equipment while

dispatching, after approval of Project Manager.

23. DEVIATIONS :

The deviations between these CTPT sets and NABL approved Standard Lab (CPRI, ERDA, etc.,) type testedCTPT set along with detailed reasons for deviations if any shall be submitted along with tender.

24. TOLERANCES :

Unless otherwise specified herein the test value of the transformers supplied should be within the tolerancepermitted in the IS on the guarantee values.

25. SEALING OF CTPT SETS AFTER TESTING AND INDIVIDUAL TEST REPORTS :

After witnessing testing on sample quantity and physical inspection of all offered CTPT sets, the purchaser‟srepresentative will provide numbered plastic seal bits to two opposite corners of tank, Secondary Chamber of alloffered CTPT sets, for delivery of correct inspected materials only. The manufacturer has to provide test reportduly mentioning all test results, seal bit numbers and name & address of Employer representative after inspectionis over. The seal bit numbers shall also be mentioned in the test reports signed by Employerrepresentative submitted for delivery instructions.

26. INSPECTION AND TESTING OF TRANSFORMER OIL :

To ascertain the quality of transformer oil the manufacturer’s test report should besubmitted at the time of inspection. Arrangements should also be made for testing the transformeroil, after taking out the samples from the manufactured CTPT sets and tested in the presence of Employerrepresentative (or) if desired, in an independent laboratory manufactured CTPT sets and tested in the presence ofEmployer representative (or) if desired, in an independent laboratory.

27. DEPARTURE FROM SPECIFICATION:

If the tenderer wishes to depart from this specification in any respect, he shall draw the attention to suchpoints of departure explaining fully the reasons therefore. Unless this is done the requirements of thisspecification will be deemed to have been accepted in every respect.

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28. NAME PLATE :

The Purchase order No. and Date of purchase order, the words “PROPERTY OF EMPLOYER NAME”. The name

plate shall be non-detachable type & fixed with rivets, not with bolts & nuts. The name plate should bear year &month of manufacture & other data as per IS. Space should be provided to punch the date of installation by user

group.

29. The tenderer shall indicate the source of all materials. He shall also indicate the name of the manufacturer and makeof conductor, Transformer oil Electrical Steel Laminations, Construction Steel etc.

30. FITTINGS :

The following fittings/accessories are to be provided to the CTPT units.

a) Rating and terminal marking plates non detachable - 1no.

b) Earthing terminal swith bolt, nuts & washers for connecting earth wire -2Nos.

c) Lifting lugs -4Nos. for main tank and 2Nos. for top cover.

d) Pressure relief valve.–1no.

e) Bimetallic terminal connectors on the HV bushings–6Nos.

f) HV bushings Outdoor –6Nos.

g) Secondary terminals bushings– 10Nos

h) Base channels 75 x 40 mm.

i) 66 months guarantee embossed plate welded to tank opposite side of name plate.

j) Tank and over all dimensions.

k) Weight content of a) core b) windings c) tank & fittings d) weight/qty. of oil e) overall weight.

SCHEDULE OF MATERIALS :

Sl. No. Name of the Materials


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TECHNICAL SPECIFICATION FOR ENERGY METER

1.1 GENERAL

This Chapter describes the common requirement for static energy meter required for HT feeder, 3-phase DistributionTransformer, 1-phase Transformer.

CMRI along with software shall be supplied for each package as per BPS. Necessary software for downloading the datathrough CMRI and uploading to computer shall be provided.

The seals & sealing specifications are given in Annexure A.

1.2 STANDARDS APPLICABLE

Unless otherwise specified elsewhere in this specification, the performance & testing of the meters shall conform to the

following Indian/International standards with updated and latest amendments/revisions thereof.

S. No. Standard No. Title

1. IS 14697-1999 AC Static Watt-hour Meters for active energy Class 0.5 & 0.2

2. BIS 12063 Specification for degree of protection

3. IS 5133/1969 Specification for boxes for enclosure of electrical accessories

4. IEC 60687 Specific for AC static Watt hour meter class 0.5 & 0.2

5. IS 13779/1999 AC Static Watthour Meters for active energy Class 1.0 & 2.0

6. IS 15959/2011 Data Exchange for Electricity meters

7. IEC 61036/1996 Specific for AC static Watt hour meter class 1.0 & 2.0

8. CBIP Report No.-88 Specification for AC Static Electrical Energy Meters

9. CBIP Report NO-325 CBIP Guide on Static Energy Meter- Specifications and testing

10. CBIP Technical Report No.111

Specification for common meter reading instrument

11. IS;9000 Basic environment testing procedure for electric and electronicitem

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Note: The meters should be DLMS compliant and conform to Indian Standard IS:15959 and its relevantamendments.

1.3 CLIMATIC CONDITION

The meter should be able to perform satisfactorily in moderately hot and humid climate, conducive to rust and fungusgrowth as specified in Section-I. The climate conditions are also prone to wide variations in the ambient conditions. Themeter shall work satisfactorily even under lightning conditions and also the meter performance and life shall not be affecteddue to smoke present in the atmosphere.

* The specifications are applicable for meter installation upto an altitude of 2200 meter above mean sea level. For meters tobe used for an altitude of above 2200 MSL necessary corrections shall have to be carried out in BIL and one minute powerfrequency with stand voltage capability as per relevant standard.

1.4 GENERAL TECHNICAL REQUIREMENTS :

Typeofmeter

InputVoltag e

InputCurren t

Burden Type/Phas e

StartingCurrent

Accuracy

HTFeedermeter

3 x 110

voltphase to

phase

5A 1.5 Watts/phase or10 VA/phase forvoltage circuit and1 VA per phase forcurrent circuit

3 phase4 wire

0.1 %of basic

0.5

Note: The input voltage of CT operated meter will be 230 volts or 240 volts or 250 volts. (BPS shall specify therequired voltage for the project.).

1.5 POWER FACTOR RANGE

The meter shall be suitable for full power factor range from Zero (lag) to Unity to Zero (lead).

1.6 POWER SUPPLY VARIATION

Energy meter along with its accessories shall withstand following extreme operating conditions. Voltage: 60% to 130 % of V ref

Frequency : 50 ± 5% Hz

The manufacturer can also offer meters, which can withstand higher variations. Meter should maintain its accuracy in lowvoltages also.

Note: The meter shall withstand phase to phase voltage between phase and neutral for 15 mins without damage and keep registeringenergy.

1.7 MAXIMUM CONTINUOUS CURRENT

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The maximum continuous current in meters shall be the current at which the meter purports to meet the accuracyrequirement of the specification. Meter terminals should be able to carry 150%Imax for two hours continuously

1.8 CALLIBRATION

The meter should be only factory calibrated and no modification of calibration should be possible at site to ensure non

tampering of meter at site.

1.9 COMMUNICATION CAPABILITY

The Meter shall be provided with a galvanically isolated optical communication port as per IEC-1107/PACT/ANSI, with

removable cover and with locking arrangement so that it can be easily connected to a CMRI for data transfer.

The optical communication port shall also have sealing provisions. The manufacturer shall provide the requisite meter software,protocol software or any other software and all facilities required by the owner to use the WINDOWS based hand held CMRI forreading and retrieving the data from the meter and download them in owner’s base computer station. The contractor shalldemonstrate the data transfer through hand held CMRI and generating the appropriate reports to owner.

The meter shall have one RS-485/232 port in the form of Rj11 near the terminal block and should not be accessible aftersealing of terminal cover. It shall be used for remote communication with the central server station/SCADA via modemconnected to the port as per the relevant DLMS protocol. The data should be transferred at a baud rate of 9600 as per DLMSprotocol.

1.10 NAME-PLATE MARKING OF THE METER

The marking on every meter shall be in accordance with relevant clauses of standard.

Every meter shall have name plate beneath the meter cover such that the name plate cannot be accessed without openingthe meter cover and without breaking the seals of the meter cover and the name plate shall be marked distinctly andindelibly. The basic marking on the meter nameplate shall be as follows :

a) Name of Project

b) Manufacturer’s name & trade markc) Type Designation

d) No. of phases & wirese) Serial number

f) Month and Year of manufactureg) Reference Voltage

h) Rated currenti) Reference Standard as applicable

j) Principal unit(s) of measurementk) Meter Constantl) Class index of meterm) Property of <Name of owner>n) Purchase Order No. & Date

o) Guarantee period

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1.11 CALIBRATION AND TEST OUTPUT

The meter should have test output accessible from the front and be capable of being monitored with suitable testingequipment. The operation indicator must be visible from the front. Test output device shall be provided in the form of one

common/separate LED for KWh and KVARh as applicable with provision of selecting the parameter being tested. The test output

device should have constant pulse rate in terms of pulse/unit energy.

The meter shall be tested, calibrated and sealed at works before dispatch. Further, no modification or calibration shall be

possible at site by any means.

The resolution of the test output shall be sufficient to enable the starting current test in less than 10 minutes.

1.12 INSTALLATION AND COMMISSIONING

The Bidder shall be responsible for total installation and commissioning of the meters (along with test blocks, if suppliedseparately) as per Owner's advice, including unpacking and inspection on receipt at site, mounting the meters, connectionof input & output cables to the meters including any required rewiring, functional testing, commissioning and handingover. The Bidder's personnel shall procure/carry the necessary tools, equipment, materials and consumables (includinginsulated wires, lugs, ferrules, hardware etc.).

As a part of commissioning of CMRI the Bidder shall load the software specified in this specification into the PCs at the Basecomputer stations, and fully commission the total meter reading scheme. He shall also impart the necessary instructions to Utilityengineers.

1.13 DT meters

The meter along with CT Housing Cabinet shall be suitably mounted in the pole of DT. The optical communicationport of the meter , provision for modem fixation and other communication port for AMR shall be provided in the D.Tmetering box , with proper clamping on the pole up to the height of 2.5 meters from the ground level. At least 0.5meters of cable shall be freely looped inside the box for ease of connection with CMRI. The meter with outdoorcabinet and CT housing cabinet to be supplied by the contractor.

1.14 GUARANTEE

Manufacturer shall undertake a guarantee to replace the meters upto a period of 66 months from the date of operation.The meters, which are found defective/inoperative at the time of installation, or became inoperative/defective within the

guarantee period, these defective/inoperative meters shall be replaced within one month of receipt of report for such

defective/inoperative meters.

1.15 SERVICES

Manufacturer shall also extend services to repair the meters on chargeable basis, up to a period of 108 months from the datewhen the guarantee period is over i.e. after 66 months of successful operation of the instant meter.

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2.1 3 PHASE 4 WIRE 0.5 CLASS ENERGY METER FOR FEEDER (DLMS Compliant category A meters)

2.2 GENERAL & CONSTRUCTIONAL REQUIREMENTS

2.2.1 Meters shall be designed and constructed in such a way so as to avoid causing any danger during use and under

normal conditions. However, the following should be ensured :

a) Personal safety against electric shock.

b) Personal safety against effects of excessive temperature.c) Protection against spread of fire.

d) Protection against penetration of solid objects, dust & water.e) Detection against fraud.

f) Detection against pilferage.

2.2.2 The meter shall be designed with application specific integrated circuit and shall be manufactured using SMT (SurfaceMount Technology). Power supply and voltage divider circuits may be of PTH technology. The meter should behoused in a safe, high grade engineering plastic / polycarbonate casing, which is of projection mounting type and isdust/moisture proof, conforming to IP-51 of BIS 12063 / IEC 529.

2.2.3 All insulating material used in the construction of meters shall be non-hygroscopic, non-ageing and of tested quality.All parts that are likely to develop corrosion shall be effectively protected against corrosion during operating life by

providing suitable protective coating.

2.2.4 The meter shall be supplied with a transparent extended terminal block cover (ETBC). The meter base, meter cover,terminal block and ETBC shall be made of unbreakable high grade fire resistant non-flammable reinforced,polycarbonate (not bakelite) or equivalent high grade engineering plastic, which should form an extension of metercases and have terminal holes and shall be of sufficient size to accommodate insulation of the conductors, meetingthe requirement of CBIP technical report CBIP.88.

2.2.5 The extended terminal block cover should be separately sealable at two places and housed at the bottom of the

meters and once sealed should prevent unauthorized tampering.

2.2.6 The terminal block should have sufficient insulating properties, mechanical strength and should have tin plated solid

brass terminals with two fixing screws per terminal. The terminals should be designed to withstand high overload.

2.2.7 The meter should not get damaged or substantially influenced by the electromagnetic disturbances and electrostaticdischarges caused by harmonics, voltage dips and short interruptions, transients, DC and AC magnetic field.

2.2.8 The meter shall have an operation indication device such as a blinking LED/ LCD. The operation indicator shall bevisible from the front window and capable of being monitored conveniently with suitable testing equipment.

2.2.9 The meter shall conform to the degree of protection IP 51 but without suction in the meter as per IS: 12063/IEC:529 for protection against ingress of dust, moisture and vermin.

2.2.10 The meter-base, meter cover, terminal block and ETBC shall be made of unbreakable, high grade, fire resistant,reinforced, non-flammable, polycarbonate or equivalent high grade and good quality engineering plastic.

2.2.11 The terminal block, the ETBC and the meter case shall ensure reasonable safety against the spread of fire. Theyshould not be ignited by thermic overload of live parts in contact with them.

2.2.12 The meter shall have Zn plated MS/Nickel plated Brass terminals. The terminals shall have suitable constructionwith barriers and cover to provide firm and safe connection of current and voltage leads of stranded copperconductors or copper reducer type terminal ends (thimbles).

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2.2.13 The manner of fixing the conductors to the terminal block shall ensure adequate and durable contact such that thereis no risk of loosening or undue heating. Screw connections transmitting contact force and screw fixing which maybe loosened and tightened several times during the life of the meter shall be such that the risk of corrosion resultingfrom contact with any other metal part is minimized. Electrical connections shall be so designed that contactpressure is not transmitted through insulating material. The internal diameter of the terminal holes shall be 5.0 mmminimum. The clearance and creepage distance shall conform to relevant clause of IS 14697:1999/CBIP technicalreport No. 88.

2.2.14 The meter shall be compact in design. The entire and construction shall be capable of withstanding stresses likely tooccur in actual service and rough handling during transportation. The meter shall be convenient to transport andimmune to shock and vibration during transportation and handling.

2.2.15 The meter shall have a design to operate satisfactory for 10 years under normal electrical condition and guaranteedlife of 18 months from the date of commissioning against manufacturing and design defects. The meters founddefective with in guaranteed period shall be replaced by manufacturer free of cost within one month of intimation.

2.2.16 The meter shall be provided with accurate quartz crystal based real time clock and calendar with the accuracy limitas per relevant standards. Meter shall have provision to synchronise the meter time with standard time throughCMRI with proper security system.

2.2.17 The integration period shall be set as 30 minutes and subsequently can be changed on real-time basis.

2.2.18 Vendor will give one copy of all the software’s (meter reading software for CMRI, software for uploading data fromCMRI to computer).

2.2.19 It should be possible to check the healthiness of phase voltages by displaying all the voltages on the meter display.

2.2.20 The Meter should have battery backup to be read in absence of Power Supply.

2.2.21 The meter should work accurately irrespective of phase sequence of the mains supply.

2.2.22 The meter should remain powered up and functional even when either any two phases are available to the meter.

2.2.23 The meter shall record active energy, even if one or more CT”s are reversed. The current vector direction shallalways be considered as positive (import) for computation of energy and shall be added in main active energyregister.

2.2.24 Data Security: The Meter shall have multilevel password for data protection and security. The meter data retrievalshall be possible through authenticated CMRI. The meter shall support the event of change of TOD register timings /no. of TOD registers, demand integration period and /or setting the meter time through authenticated transactionand shall be logged as an event. The transaction events shall be available for viewing at BCS end.

2.2.25 The meter data shall be retrievable through CMRI and will be downloaded in the Base computer software for viewing,analysing and printing. The meter data downloaded at BCS end should be in user-friendly formats. The manufacturershall supply the required software for base computer system. The base computer software shall have the facility toconvert the required data (For billing, Energy Audit, tamper analysis purpose) in to ASCII format. This data should bepossible to be used as input data for any other software to generate desired reports as per the utility requirement.

2.2.26 The meter shall have radio interference suppression such that it should not generate noise, which could interferewith the other equipment.

2.2.27 The meter shall have three fixing holes, one at the top and two at the bottom. The top hole shall be provided with aspecial clip at the back of the meter so that holding screw is not accessible to the consumer after fixing the meters.The lower fixing screws shall be provided under the sealed terminal cover. The requisite fixing screws shall besupplied with each meter.

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2.3 SEALING OF METER

Reliable sealing arrangement should be provided to make the meter tamper proof and avoid fiddling or tampering byunauthorized persons. For this, at least two no. of seals on meter body, two no. of seals on meter terminal cover and one no. ofseal on each communication port shall be provided. All the seals shall be provided in front side only. Please referAnnexure A for specification for sealing system. The meter cover and base should be ultrasonically/chemically

welded on at least three sides of the meter so that if the meter cover is opened there is clear evidence of tampering andthe meter should be completely broken.

2.4 CONNECTION DIAGRAM & TERMINAL MARKINGS

The terminals shall be marked properly on terminal block for giving external connections. A diagram of connections should beprovided inside the cover of terminal block. The terminal cover shall be extended such that when it is placed in position it is notpossible to approach the connections or connecting wires. The terminals and the screws shall be suitable to carry upto 150% ofImax safely. The terminals shall have suitable construction with barriers and covers to provide secure and safe connections.

2.5 REMOTE READOUT FACILITY, COMMUNICATION CAPABILITY

The meter also shall have a separate individually sealable RS-485 communication port to communicate with Remote TerminalUnit (RTU) over DLMS protocol in multi-drop mode so that selected analog data can be communicated to central location for

SCADA / DMS application. The implementation detail of DLMS protocol shall be furnished by the bidder.

2.6 SOFTWARE

Licensed copies of the software (meter reading software for CMRI, software for downloading/uploading data from CMRI tocomputer) shall be made available and shall be installed on each common meter reading instrument (CMRI) and Base computer

by the manufacturer.

Common Meter Reading Instrument (CMRI) would be loaded with user-friendly software (MS-DOS 5.0 or higher versioncompatible) for reading, downloading meter data and Time of Day (TOD) programming in the meter.

Windows based user interactive Software for receiving data from CMRI and downloading instructions from base computer toCMRI. This software should have, amongst other requirements, features and facilities as described later in this specification, thefacility to convert meter reading data into a user definable DBF (Access) or spreadsheet or ASCII format or any other formatfor integrating with the Employer's billing system as desired/required by the utility. Here again an "Export wizard" or similarutility shall be available whereby user can select file format, the variable data to export, the field width selection of eachvariable so that it may be possible for the user to integrate the same with the user’s billing data and process the selected data indesired manner.

The software shall have the flexibility to generate the following sets of reports :

• Load survey reports

• Tamper reports

Necessary software for loading application program into meter via CMRI serial port shall also be provided. The BCS

should incorporate the following points:-

1. Line graph should be provided in load survey of the BCS2. There should be provision for daily, weekly and monthly viewing of meter DATA.3. There should be provision for meter serial number/date wise viewing of meter DATA.4. The load survey should be consist of voltage, energy, maximum demand and power factor. Theseparameters should be on selectable basis.5. In the bar graph of the load survey in BCS, the thirty minutes maximum demand integration period

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should have accurate values up to the last three decimal point.6. All temper should be logged properly with date and time.7. Maximum demand values and other parameters in the load survey of the BCS should be logged andvisible properly with date and time on pointing of the cursor on the graph.8. BCS should be operable through single window and user friendly

2.6.1 Tamper reports to include for a pre-determined duration or month wise, tamper count, tamper duration and tamper

history for each of the meters.

2.6.2 There should be provision to synchronize RTC (Real Time Clock) of the meter through CMRI/BCS and it should bepassword protected.

2.6.3 Vendor will provide soft copy of all the software in CD form along with the meters supplied.

2.6.4 Vendor to install & demonstrate working of software programmes of other meter manufacturers on the CMRI’s to be

supplied with this package.

The specification of CMRI are presented as Annexure B.

2.7 DISPLAY

A real time quartz clock shall be used in the meter for maintaining time and calendar date. The maximum drift shall not exceed3 minutes per year. The uncertainty of setting initial time shall not exceed + 30 Seconds with respect to Indian standard time(Ref NPL New Delhi).

Facility for adjustment of real time shall be provided through CMRI with proper security.

The meter shall have a minimum 7 digits, 7segment display of liquid crystal display (LCD) or light emission diode display(LED) with another digit for legend. The minimum character height shall be 10 mm. Provision shall be made to read

consumption in either whole units or decimal multiples or sub-multiples of one possible to display content of relevantparameters with another digit displaying legend for identification.

The display shall remain on the screen till operator presses button for subsequent display or 10 sec which ever is earlier.

The meter should have non-volatile memory, so that the registered parameters will not be affected by loss of power. Aprovision shall be made to read the meter parameters such as MD and consumption, etc., through the meter cover withoutactually opening the meter box cover. The non-volatile memory should have a minimum retention time of 10 years underunpowered condition.

2.8 DISPLAY SEQUENCE

The meter shall display the required parameters in two different modes as follows :

A. Auto Display Mode :

Display test (LCD/LED Segment check)

• Real time & date

• Active energy forwarded• Reactive energy lag• Reactive energy lead• Apparent energy forwarded• Last bill Active and Apparent Energy

• Last bill Maximum Demand in kVA• Average Bill Power Factor

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• Maximum Demand forwarded• MD occurrence date and time• Rising demand with elapsed time

• MD reset count• Cumulative MD forwarded• Instantaneous average 3 φ PF

• Instantaneous frequency

• Phase voltages R,Y,B

• Phase currents R,Y,B

• Cumulative power on hours of current month

B. Push Button Mode :

All above & the following :

• Tamper and fraud details• Present CT status

• Last occurrence tamper ID• Date and time of last tamper occurrence

• Last restoration tamper ID• Date and time of last tamper restoration• Cumulative tamper count• TOD Register [Active forwarded energy (8 Nos)]• TOD Register [Apparent forwarded energy (8 Nos)]

• TOD Register [Apparent forward MD (8 Nos)]• Cumulative power on hours

C. Read Out Parameters with CMRI :

All above including following :

• Energy registers• Billing registers

• TOD Registers• Load survey data• Tamper and fraud (all event details with date and time)

• Self diagnostic details• Real time calendar clock fail• Battery bad flag

• History of monthly Energy Flow, Maximum Demand, Average power factor for the last 12 months

2.9 MAXIMUM DEMAND REGISTER

The maximum demand is to be monitored during each demand interval set with 30 minutes integration and the maximumof these in a month shall be stored. Whenever MD is resent the maximum demand value so registered shall be storedalong with date and time. Under the current integration period, the rising demand should be displayed continuously alongwith the elapsed time. The registered demand and the number of times the MD is reset shall also be displayed and theinformation stored.

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2.10 MAXIMUM DEMAND RESET

Facility for auto reset of MD at 00.00 hrs of first of every month shall be provided for which minimum 30 years calendarshall be programmed by the manufacturer.

The meter shall display the maximum demand reset count.

2.11 LOAD SURVEY CAPABILITY

Load survey shall be available for at least 45 days with 30 minutes load survey integration period for followingparameters. Vendor shall provide necessary facility to transfer data through CMRI/Public Switch Telephone Network- PSTN/Low

Power Radio (LPR)/GSM.

a. kWh forwarded

b. kVAh forwarded

c. kVARh lagd. Voltage Phase wise

e. Current Phase wise

f. Daily maximum demand active & Apparent.

The load survey data, abnormality event information and instantaneous parameters data shall all be retrievable throughthe meter's communication port from a common meter reading instrument (CMRI)/ Hand Held Unit and shall be transferred(downloaded) to a PC with user friendly Windows based software to get complete details in numerical and/or graphic form. Thenecessary feature shall be available in the software used for uploading data from CMRI to computer and shall be provided bythe manufacturer with complete details.

The meter shall have sufficient non-volatile memory for recording history of energy parameters for last twelve billing cycles (Bill

date shall be 00 hrs of the 1st date of the calendar month by default – programmable) and information should be made

available at the BCS end.

2.12 TIME-OF-DAY (TOD) TARIFF/DEMAND

The meter should have provision of registering the time-of- day energy and maximum demand. It shall be possible to define TOD

register for active forwarded, apparent forwarded energy type.

The meter should have in-built capacity to define up to eight (8) time zones through operation of CMRI.The change of theTOD time-period(s) or changing number of TOD zones should be possible through CMRI with special authenticatedcommand from the software used for uploading data from CMRI to computer so that only authorised person(s) can make suchchanges. The main control of this system along with proper security password/code should be available on one or morecomputers located at the authorised location(s) as per the directions to be given by the Employer.

2.13 SELF DIAGNOSTIC FEATURE

2.13.1 The meter shall be capable of performing complete self diagnostic check to monitor the circuits for anymalfunctioning to ensure integrity of data memory location at all times. The meter shall have indications forunsatisfactory/nonfunctioning/malfunctioning of the following :

a) Real Time and Date

b) All display segments as per the requirement

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c) Nonvolatile memory (NVM) failure indication at BCSd) Low battery indication at BCS

2.13.2 While installing the meter, it should be possible to check the correctness of Current and Voltage Transformer

connections to the meter and their polarity from the functioning of the meter for different voltage injections with thehelp of vector/phasor diagrams. For this purpose a suitable software for field diagnosis of meter connections with

the help of Meter Reading Instrument should be supplied.

2.14 TAMPER & FRAUD PROTECTION

The meter shall function properly under following common abnormal conditions :

1. Phase sequence reversal The meter shall keep working accurately irrespective of the phase sequence of thesupply.

2. Current reversal/CTpolarity reversal

The meter shall log energy in forward direction even if the current is flowing inreverse direction in one or more phases.

3.External magneticInfluence

The metering system shall be provided with adequate magnetic shielding so thatany external magnetic field (AC Electro Magnet or DC Magnet) as per the valuesspecified in CBIP Technical Report No.88 (with latest amendments) applied on themetering system shall not affect the proper functioning and recording of energy asper error limits prescribed by CBIP.

4. 35kV spark discharge The meter shall be immune to application of 35kV spark discharge for min 10minutes.

5. Jammer The meter shall be immune to application of high frequency jammer.

Beside this the meter should have features to detect the occurrence and restoration of, at least, the following abnormalevents :

i. Missing Potential & Potential imbalance : The meter shall be capable of detecting and recording occurrence andrestoration with date and time the cases of Potential failure which could happen due to disconnection ofpotential leads (one or two), failure of phase line fuse from the Potential Transformer primary side. Meter shallalso detect and log cases of voltage unbalance (from 5% for more than 5 minutes or more (programmable)) ofvoltages.

ii. Voltage High / Voltage Low : In case the average 3 phase voltage remains less (below 0.75Vref by default)than or above (above 1.15Vref by default) for a predefined period (30 minutes by default), the meter shall logsuch incidences with date & time. The voltage thresholds & persistence time shall be programmable using theCMRI & BCS. This abnormal condition shall be logged only when all the three-phase voltage is available.

iii. Current imbalance: The meter shall be capable of detecting and recording occurrence and restoration with date

and time of Current unbalance (30% or more for more than 15 minutes, or as programmable).

iv. Current Circuit Short: The meter shall be capable of detecting and recording occurrences and restoration ofshorting of any one or two phases of current circuit to identify events like CT saturation, CT lead shorting, CT

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inter turns short etc.

v. Current Circuit Open: The meter shall be capable of detecting and recording occurrences and restoration ofopening of any one or two phases of current circuit which can happen due to intentional / accidentaldisconnection of current circuits. The meter shall be able to log abnormality conditions in current open eventlike CT leads burns, loose connection, CT winding open etc in the meter memory. No load condition should notbe recorded in meter memory as a Current circuit open event.

vi. Power on/off: The meter shall be capable to record power on /off events in the meter memory. All potential

failure should be recorded as power off event.

vii. Cover Open: The meter shall be able to detect cover open occurrence event if cover is opened in mains

on or off condition. Separate legend for cover open event shall be made available on LCD. This legend

shall remain in on state till meter reading so that it will come in to notice of meter reader. This

tamper should be logged as non-rollover event.

The meter shall record the total duration of the above abnormalities, time and date of their occurrences & restorationswith a snap shot of electrical conditions viz. Voltage , current ,PF etc

Logic for calculation of voltage and current imbalance shall be furnished by the tenderer.

The meter shall keep records for the minimum last 250 events (occurrence + restoration) for above of abnormal conditions.It shall be possible to retrieve the abnormal event data along-with all related snap- shots' data through the meter's optical portwith the help of a hand held unit (HHU) and download the same to the BCS where it shall be available for viewing. All thisinformation shall be made available in simple and easily understandable format.

2.15 TAMPER LOGIC

Properly designed meter event logic should be provided. There shall be separate compartments for logging of potentialrelated event, current related event and power on/off event. The bidder should explain the events details in each compartmentunder their offer.

The logging of various events in each compartment should be as under :

Once one or more compartments have become full, the last event pertaining to the same compartment will be enteredand the earliest (first one)-event should disappear. Thus, in this manner each succeeding event will replace the earliest

recorded event, compartment wise. Events of one compartment/category should overwrite the events of their owncompartment/category only.

A properly defined meter tamper logic should be provided. The tamper logic should be capable of discriminating the systemabnormalities from source side and load side and it should not log/record tamper due to source side abnormalities.

There shall be three separate compartments for logging of different types of tampers as follows :

• Compartment No. 1:50 % of the tamper memory space shall be allocated for the following current related tampers

- CT open circuit- CT short (bypass)

• Compartment No. 2:25 % of the tamper memory space shall be allocated for missing potential tampers.

• Compartment No. 3:25 % of the tamper memory space shall be allocated for current unbalance tampers

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2.16 TESTS

Unless specifically waived off all test shall be witnessed by the Employer.

2.16.1 Type Test

Energy Meters offered shall be fully type tested as per IS 14697 / CBIP Technical Report No. 88 at any of the NABL accreditedtest laboratories.

In case meters are not type tested in NABL accredited test laboratories the bidder shall arrange to carry out type tests inany of the NABL accredited test laboratories at his own cost.

2.16.2 Acceptance Test

Acceptance test shall be carried out as specified in table 18 of CBIP Technical Report No. 88

2.16.3 Routine Test

All routine tests as specified in table 18 of CBIP Technical Report No. 88 shall be carried out on each individual meter.

2.17 FIXING OF METERS

The meters shall be mounted in the panels.

2.18 OTHER SALIENT FEATURES

2.18.1 It should be possible to check the healthiness of phase voltages by displaying all the voltages on the meter display.

2.18.2 The meter shall have provision of reading through communication port in the absence of power through a backupinternal battery.


2.18.4 The meter should remain powered up and functional even when either of the two phases or one phase along withneutral is available to meter.

Annexure-A : SPECIFICATION OF POLY CARBONATE SEALS FOR SEALING OF POLY PHASE METERS

1.1 Seal should be made of polycarbonate with ultra violet additive & should not be affected by boiling water & acid.

1.2 The seal should withstand temperature up to 147 ° C.

1.3 Seal should be available in Clear / Red / Blue / Yellow / Amber / Green / Grey colour and should be transparent.

1.4 Every seal should have 6” long, 20 gauge, twisted strand stainless steel wire.

1.5 Seal should have facility to print mono gram / name of company.

1.6 Every Seals should have a unique seven-digit number. Numbers shall be printed on seal including the anchor cap-

using laser marking which shall not be erased using any tool or by any chemical reaction. Both the seven digit sealnumbers should be visible separately after closing the seal.

1.7 Seals should have tamper proof, internal “ anchor “ locking mechanism that permanently secures the wire upon

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closing. The mechanism should be designed in such a way that its original position can’t be restored after any effortof tamper or breaking of seals.

1.8 Sealing mechanism shall be designed in such a way that it can be sealed without using any pliers or tools.

1.9 Seal should be constructed of two parts, first the main body (female type) & second the anchor (male type) havinglocking mechanism. Both the part should be designed in such a way that once the seal is closed the two parts can’tbe separated.

1.10 Seal should be patented. Copy of patent shall be submitted along with offer.

1.11 Packaging: Seals shall be supplied in packet of 100 seals. Each packet shall be labelled for following information :

• Client Name

• Purchase order number &date

• Serial number range in the form of bar coding.

1.12 Seals shall be provided with tracking & recording software. The software shall have following features :

• Software should have facility of defining the system controller

• Facility to enter serial number of seals with the help of bar code scanner.

• Receiving of seal in the system and with authentication like signature.

• Facility to identify the concern who is responsible for receiving of seals and nominated by system supervisor.

• Provision to define different type of seals for various uses.

• Software should have facility of report generation for inventory & issue records.

• Facility to track for relevant data for individual seal entered in the system.

8. METER CABINET FOR HT METRING ASSOCIATED WITH CTPT SET FOR 11KV FEEDERS:

The technical specification and drawing of the meter cabinet will be as per APDCL existing specification for housing the meter.

9. EARTHING:

Earthing of CT-PT set, Meter cabinet and other iron materials of feeder metering system are to be done with one GI pipe of 3

meter long and 6 swg GI wire in each metering system as per relevent IE rules

Annexure-B : TECHNICAL SPECIFICATION FOR COMMON METER READING INSTRUMENT (CMRI)

This specification covers supply and delivery of Common Meter Reading Instrument (CMRI) for reading (uploading) the data of

different make of meters and to have a capability to dump (download) the same to the base computer system. The CMRI

shall have memory / space to reside software of reading at least 3 different makes of electronic meters as specified byEmployer.

10. Portable / hand-held Common Meter Reading Instrument (CMRI) :

These shall be tailor-made for tapping all data stored in the memory of electronic meters of type, three phase 3wire, threephase 3 wire HT/LT Trivector meters, whole current meters, single phase meter, and faithfully transferring it to the local PC in

the BCS. Each device shall be supplied complete with :

i) a lead with optical head for coupling it to the meter

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ii) a lead for plugging it to a personal computer

iii) an internal battery for powering the devices

iv) a case for safely carrying it about

v) a battery charger

The total arrangement shall be such that one (1) operator can carry out the whole operation himself, in about five

(5) minutes per meter.

B. The CMRI shall have a key for starting the data tapping from the coupled meter’s memory, a key to start datatransfer to the PC, and a lamp, which would light up on completion of data collection, remain ‘on’ while the data isheld in the device and would go ‘off’ when all data has been transferred to the PC. Data tapping operation shall noterase the data from the meter’s memory, or effect the meter operation in any way. The memory of the CMRI shallget automatically cleared when the data has been transferred to the PC only then the CMRI shall accept data fromanother meter. CMRIs shall also have the necessary provision for meter clock correction. CMRIs should haveadequate memory, to host application software, for enabling downloading of meter data of 3 makes of meters.

C. The Contractor shall provide the necessary software which would enable a local IBM-Compatible PC to (i) accept the

data from the CMRI and store it in its memory, (ii) display the collected data on PC’s screen, with forward/backward

rolling, (iii) print out the data collected from one or more meters, starting from a certain date and time, as per

operator’s instructions, (iv) transmit the collected data through an appropriate communication link to the central

computer, starting from a certain date and time, as per operator’s instructions, and (v) store the collected data on a

floppy disc.

D. The above software shall further ensure that absolutely no tampering (except total erasures) of the collectedmetering data is possible during its handling by the PC. The software shall be suitable for the commonly available

PCs, and shall be supplied to SEB in a compatible form to enable its easy loading into the PCs available (or to beinstalled by the SEB) at the various substations/ locations in the circle.

E CMRI should be compatible with Low Power Radio module to be provided by the bidder for receiving the data fromthe meter to the CMRI/Hand Held UNIT and ultimately transferring to BCS &vice versa for loading requiredinstructions to the meters.

F. CMRI should conform to CBIP Technical Report No. 111with latest amendments with Level (2) IP 67 protection and

following climatic condition & standards.

11. StandardsThe CMRI shall confirm in all respects to the following standards :

i) CBIP Technical Report no. 111 – Specification for common Meter reading Instrument.

iii) IEC – 529 – Degree of Protection provided by enclosures

iv) IS : 12063 : 1987 – Classification of Degree of Protection provided by enclosures of electrical items

v) IS 9000: 1979 – Basic environmental testing procedure for electronic & electronic items.vi) IEC – 1000 – Electromagnetic compatibility

vii) IEC – 1000-4-2 : 1995 – Electrostatic discharge immunity testviii) IEC – 1000–4-3 : 195 – Radiated, radio – frequency electromagnetic field immunity test, Magnetic immunity testix) CISPAR 22 – Limits and method of measurement of radio disturbance characteristics of information technology

equipment.

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2.0 Climatic Conditions :

The detail climatic condition is specified in Section-I.

3.0 Principal Parameter :

For downloading data from electronic meters of type, single phase,230 V, whole current, three phase 415 V Whole current,three phase 415 V,CT operated, 33kV,11kV,HT Trivector CT,PT operated meters. The offered meter reading device should beportable, compact and battery powered. It’s memory shall be adequate to enabling transfer of data from three makes of metersequipped with suitable communication port and transferring them on to a base computer system such as an IBM compatible PCor an external peripheral & vice-versa.

The offered CMRI should have capacity compatible to read minimum 20 meters for billing & tamper data but without load

survey and minimum 10 meters for billing and tamper data with load survey.

CMRI shall be able to display phase / vector diagram of phase current, phase voltage with respective phase angles and phasesequence of voltage at SITE when these data are read from the meter.

4.1 GENERAL TECHNICAL REQUIREMENT :

Physical Characteristics :

i. Size :

CMRI should be handy, lightweight and small in size for ease of portability.

ii. Enclosure :

iii. CMRI casing shall be of electrical insulating material of high thermal stability and mechanical strength. Its degree ofprotection confirms to IP 67 LEVEL (2) as per IS 12063 / IEC-529.The enclosure should be solvent resistant and shallbe provided with a suitable holding Strap for proper gripping.

iv. Ruggedness : CMRI is able to withstand harsh field environment without physical damage or loss of data.

v. Display : The display of CMRI is having the following characteristics :

a. Easy readability in varying ambient light conditions.

b. 4 lines and 20 characters per line on the screen

c. The size of the character shall be 4 mm

d.The contrast and intensity control to get a clear display in varying ambient light.

vi. Key Board : The keyboard of the CMRI is having the following attributes :

a. Long operation life i.e. minimum 100000 operations (typical).

b. Feed back for key press acknowledgement to user.

c. Legible and non-fading keypad imprints for all alphanumeric characters/symbols.

d. Each English alphabet shall have a separate key.vii. Input / Output ports (I/O Ports) :

The CMRI shall be having two serial input/output Ports, one port shall be serial port RS 232C compatible.Another optional port can be used for convenience of connecting peripherals such as bar-code reader, printer,battery charger, loader charger etc.

The offered CMRI shall be able to provide power supply for optical sensor used for meter reading applications.

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5.1 Physical interface :

i. Interface between meter and CMRI :

The interface between a meter and CMRI shall consist of 2 parts.

ii. Meter optical sensor terminating in to a 9 pin D type male connector with a cable of 500 mm +/- 10 mm. length.iii. The interface between a meter and the offered CMRI shall be with a flexible shielded cable of length 1500mm

+/-10mm having 9 pin D-type female connector with electrical circuit. This cable shall be supplied along with

CMRI. The two ends of the cable is stress relieved.

Interface between CMRI and Base computer station :

Suitable flexible shielded cable of sufficient length for communication between CMRI and base computer station shall beprovided. This communication shall be serial RS232C. On the base computer station end of the cable a 9 pin D-type female

connector shall be provided. The two ends of the cable are stress relieved.

This cable shall also be supplied along with the CMRI.

6.1 Hardware and Software requirement :

i. Operating system :

To facilitate use of various meters, specific MRI programs in one CMRI, MS DOS version 5.0 or higher system shallbe used. The facility to upgrade the BIOS/OS by a CMRI manufacturer shall be available without exposing thehardware of the CMRI.

The additional program necessary to transfer application programs with serial port shall be provided.

i. Memory :

a) The CMRI shall be having a minimum memory capacity of 3 MB Static RAM (SRAM) with battery backup andupgradeable.

b) BIOS/OS on FLASH memory / EEPROM MEMORY

iii. Communication :

The CMRI shall be able to communicate for :

a) Down loading / up loading data from / to the meter

b) Uploading / downloading data to / from the Base computer stationc) CMRI shall be capable to read bar code information using a bar code scanner from barcodes of ac static \

electromechanical electricity meters by using appropriate scanner and bar code soft ware.

d) CMRI shall support flexible baud rate ranging from 300 Baud to 19200 (or higher) Baud rates to catercommunication needs stated above.

iv. Real time clock :

A real time clock is provided in the CMRI, which have the following features :

Power requirement : The clock shall have a minimum of 15 days battery back up.

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Calendar : The clock shall have 20 years calendar.

Time drift : The time drift shall be negligible and shall not exceed 20 seconds per day.

v. Time Setting Facility :

The CMRI shall have the facility to get its time set from Base computer station. Proper security for this isensured using password.

vi. Power supply (Battery) for CMRI :The CMRI shall have the following features for its power requirements :

a) The CMRI shall be powered by rechargeable battery housed within its enclosure.

b) The average capacity of charged battery shall be sufficient to communicate with meters and basecomputer station for at least :

i) 6 hours while communicating through optical interface of meters andii) 8 hours without powering Input / Output ports for optical interface.

c) To reduce the equipment down time and inventories, there shall be provision to charge the CMRI battery

without being removed from the equipment. A suitable battery charger for charging of CMRI battery shall be

provided.

d) There would be a provision for AUTO POWER SAVE, which force the instrument in the power saving mode in caseof no activity within 5 minutes.

e) The battery used for data retention in SRAM would have a minimum of 3 years backup capacity.

f) The CMRI would have battery low indication and automatic cutoff to avoid further drain of the battery.

7.1 Communication Protocol and Software :

Software :

a) The following software shall be provided in the offered CMRI :

i) Operating system compatible to MS DOS 5.0 or (latest version ver 7.0).

ii) Necessary software for loading application programs via a serial port for uploading and down loadingbetween CMRI and Base computer Station (BCS).

b) i. Provision for loading the software into the CMRI of the specific makes of the meters, for the purpose ofreading and programming of the specific make(s) of static meters, such Software shall be provided byrespective meter manufacturers.

ii. BCS software accepting data from CMRI, processing generating reports and downloading instruction fromBCS to CMRI.

c) Special Requirement :

The offered CMRI shall have provision for storing the third party software and can also be loaded for special

applications such as manual meter reading, data entry through keyboard of CMRI, printing, display of balance

memory etc.

d) The CMRI shall have facility to draw/display vector diagram of the electrical conditions existing at site to check

the healthiness of the connections.

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e) The CMRI shall have provision to read the energy registers so that accuracy testing can be done at site with

standards calibrating equipment.

f) The CMRI shall have the provision to read the various instantaneous electrical parameters at site like voltages,

current, PF, phase angles, power (kW, KVAr, and KVA) frequency etc.

g) The CMRI shall have facility to estimate the memory space available before reading the meter.

8.0 DATA SECURITY :

The meter manufacturers are responsible for maintaining the security of the data extracted from the meters using

manufacturer specific algorithm in the software up to down loading to BCS.

9.0 CMRI shall be type tested as per clause 5 of CBIP Technical Report No. 111.

10.0 Acceptance Tests for CMRI and PC Software :

All CMRI after final assembly and before dispatch from Bidder’s/Manufacturer’s works shall be duly tested to verify that theyare suitable for supply to the Employer. In particular, each and every CMRI shall be subjected to the following acceptancetest :

(i) Functional Checks(ii) Downloading Meter Data from the Meter(s)(iii) Compatibility with PC software

(iv) Downloading the meter data on PC

(v) Functioning of advance and retard timecommands (vi) Per meter downloading timeverification

(vii) Capacity of CMRI for data storage

v) Maximum attitude above M.S.L. : 1000 Meter

vi) Average Annual rain fall : 1200 mm.

5. CURRENT AND VOLTAGE RATING :

Rated Voltage (Vref) : 240 V Phase to Neutral

Rated Current : Basic Current (Ib)- 10A and Maximum current (Imax)- 60A

6. VARIATION IN POWER SUPPLY :

The meters shall be suitable for working satisfactorily with the following power supply system variations:—

(11) Specified Operating Range : 0.7 to 1.3 Vref (-30% to +30%)

(ii) Operating voltage range for accuracy requirement : 0.85 to 1.15 Vref, i.e. –15% to + 15%

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7. FREQUENCY VARIATION :

The standard reference frequency for performance shall be 50Hz with tolerance + 5%.

8. POWER CONSUMPTION :

8.1 VOLTAGE CIRCUIT :

The active, apparent Power consumption in voltage circuit including the power supply of the meter at reference voltage,reference temperature and reference frequency shall be within limits as specified in relevant IS.

8.2 CURRENT CIRCUIT :

The apparent Power taken by each current circuit at basic current, reference frequency and reference temperature shall be

within limits as specified in relevant IS.

12 REAL TIME INTERNAL CLOCK (RTC)

12.1. RTC shall be pre-programmed for 30 Years day/date without any necessity for correction. The maximum drift shall notexceed +/- 180 Seconds per year. The uncertainty of setting initial time shall not exceed + 30 Seconds with respect to Indianstandard time (Ref. NPL New Delhi).

The clock day/date setting and synchronization shall only be possible through password/Key code command from one of thefollowing:

12.2 Hand Held Unit (HHU) or Meter testing work bench and this shall need password enabling for meter;12.3 From remote server through suitable communication network or Sub-station data logger ‘PC’

.

Note-

TECHNICAL SPECIFICATION of AAAC Raccoon conductor for jumpering etc ,Technical specification for 2.5 squaremm x 10 core stranded copper armoured cable for feeder metering specification and TS for LT XLPE

/PVC aluminum cable of size 95sqmm will be as per APDCL/DDUGJY

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GUARANTEED TECHNICAL PARTICULARS FOR 3 PHASE 4 WIRE CT/CT PT OPERATED TRIVECTOR ENERGY METER

Sl.No.

Item Bidder’s data

1 Type of Meter

2 Application3 Standard to which the meter confirm4 Rated Voltage5 Rated Current6 Frequency7 Overload capacity8 Minimum starting current in % of base

current9 Power Factor Range

10 Power loss in potential circuit11 Power loss in current circuit12 Change in error due to

a. Variation in frequencyb. Variation in temperaturec. Variation in voltage

13 Accuracy Class14 Type of Energy Registration Mechanism.15 MD Reset Mechanism16 Dynamic Working range

a) Voltageb) Current

17 Type of load (linear, non linear, balanced

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/unbalanced at any P.F.)18 Total Weight of meter

19 Dimension of the meter20 Details of meter base & cover21 Terminal Cover details22 Capability for fraud Prevention &

detection23 Sealing and Locking Arrangement24 Display details

i. Display Cycle (descriptive in order ofdisplay sequence) auto and manual

ii. Period of display of each parameteriii. Display scroll-lock facilityiv. Backlit LCDv. display off period between two cyclesvI. No of digits of display and height ofcharacter.

25 Memory Capacity26 Non volatile memory retention capacity27 Powering on facility in absence of mains28 Tamper data preservation capacity :

a) on displayb) with meter data downloadingprovisions.

29 Tamper logic in detail30 Load Survey details :

a) Parameter measured & Loggedb) Logging intervalc) No. of days of Load Survey

31 Time of the day Zone Provision32 Type of communication:

a) Local-Optical port detailsb) Additional Communication port forAMR compatibility

33 Real Time Clock34 Self Diagnostic Features (Provide

Details)35 Certification Marks

Volume-II : Section-II (B)Technical Specification

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GUARANTEED TECHNICAL PARTICULARS OF BOX

METER BOXSr.No.

PARTICULARS DETAILED PARTICULARS TO BE OFFERED BYBIDDER

1 Maker’s name To be intimated by the supplier2 Material Glass reinforced polyester sheet moulding

compound3 Grade of material SMC confirming to IS:13410:1992 grade S 14 Properties of material of construction of meter box

Flame retardant test As per IS-11731 (Min FV0)Exposure to flame (refstd IS:4249)

Self-extinguishing

Degree of protection IP-53 as per IS-12063/87Heat distortion temp. 1500C (min) as per IS:13411

5 Inside dimension ofmeter box

To be mentioned by the supplier

a. heightb. widthc. depthd. thickness

6 Earthing arrangementEarthing bolt One no. of earthing bolt of MS with 2 nuts and 2

washers shall be provided on RH side of box.Earthing sign has to be provided near to earthing bolt.

Dia & length of earthingbolts

Dia 6 mm length 25 mm

7 Locking arrangement For holding & locking of door with base two nos(min.) of “U” shaped clamps to be provided

8 Sealing arrangement Holes for wire seal9. Cable entry holes Cable entry holes 1 nos with minimum 0 19MM

polymeric gland on bottom of the box.10 Colour of box Off white11 Window having triplex

glassWindow size 140mm X 120 mm

12 Fixing of glass Fitted from inside in such a way that it can not bereplaced without opening door (with S.S. frame allaround)


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9. Earthing

(AS PER IS 3043-1987)

Earthing shall generally be carried out in accordance with the requirements of Indian Electricity Rules2003 amended from time to time and relevant regulations under Electricity Supply Authority concerned.

In case of high and extra high voltages, the neutral points shall be earthed by not less than twoseparate distinct connections with earth, each having its own electrodes sub-station and will be earthedat any other point provided no interference is caused by such earthing. If necessary, the neutral may beearthed through suitable impedance.

As far as possible, all earth connections should be visible for inspection. Each earthing system shall beso designed, that, the testing of individual earth electrodes is possible. It is recommended that thevalue of any earth system resistance shall be such as to conform to the degree of shock protectiondesired.

It is recommended, that a drawing showing the main earth connections and earth electrodes beprepared for each installation and submitted to Employer.

No addition to the current carrying system, either temporary or permanent, shall be made which willincrease the maximum available fault current on its duration until it has been ascertained that theexisting arrangement of earth electrodes, earth bus-bar etc., are capable of carrying the new value ofearth fault current which may be obtained by this addition.

All materials, fittings etc., used in earthing shall conform to Indian Standard Specifications, whereverthey exist.

GENERAL REQUIREMENTS AND PROCEDURES FOR EARTHING AT SUB-STATIONS.

The ground resistance for sub-stations should not exceed a value 2(two) ohms. The joints/connectionsin the earthling, system shall be welded only, except the connections, which require opening fortesting/maintenance. Such connections should be bolted tightly, using spring and ring washers forproper contact pressure. The G.S. flats to be provided for the horizontally laid earth grid should haveoverlap welded joints, with length of welding at least twice the width of the flat, e.g., 100 MM for 50x6MM G.S. flats. There should not be any dirt, grease, oil, enamel, paint or any such non-conductivecoatings on the surfaces being joined/ connected. Only the finished joints/connections above groundmay be provided with red-oxide or any other protective coating. Underground earth electrodes andearth grid elements, when laid, should have a clean metallic surface, free from paint, enamel, grease orany such non-conductive coatings.

As far as possible, all earth connections should be accessible for visual inspection. No cut-outs, links orswitches, other than linked switches arranged to operate simultaneously on the earthed or earthedneutral conductor and the live wire shall be inserted in the supply system. Earth electrodes or mateshould not be installed in close proximity to metal fence to avoid possibility of fence becoming live.Separate earth electrodes, isolated from the earth grid, are to be provided for grounding the fencewires.

Pipes or rods used as electrodes should be in one piece, as far as possible, with a minimum allowablelength of 3 mtrs. Except where rock or hard stratum is encountered, the pipe/rod electrodes should bedriven into the ground to a minimum depth of 3 mtrs. The strip electrodes, forming the horizontal gild,should be buried underground to a minimum depth of 0.5 mtrs. The path of earth wire should be out ofnormal reach of any person, as far as possible.


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For high resistivity soils, above 100 Ohm-mtrs., attempts should be made to bring the soil resistivity inthe range of 50 to 60 Ohm-mtrs. By digging and treating the soil mass around the earth grid/electrodeswith a mixture of salt and charcoal.

In case of rocky top soil and sub-stratum, having very high resistivity, with no scope of improvement byother means, the procedure given below should be followed:

1. At least two bores of diameter little less than 40 mm, with a minimum distance of 10 mtrs.between them, should be made in the ground at suitable locations inside the S/S yard. Theboring should be done until soil sub-stratum rich in moisture and low in resistivity isencountered. G.I. pipes of 40 MM dia. should be descended in each bore, such that, the soilmass around the pipes grips them tightly, Back – filling of bores, if required, with wet soil/claymay be done to ensure this condition. The G.I. pipes in these deep bores should beinterconnected with the main earthing grid of the S/S through 50x6 mm G.S. flat, with all thejoints/connections and terminations being either fully welded, or clamped/bolted and weldedsimultaneously. The G.I. pipes in the bores should also be interconnected with each other. Inextreme cases, the bores may have to be made at remote locations i.e. outside the S/S yard,with inter-connections, through 50x6 MM flats, as explained before.

2. The procedures to be observed stringently for making connections and joints between variouselements of the earthing system are as follows:

a. G.S. flat to Structure/flat - The G.S. flat should be welded to the metallic portion (leg) of thestructure after thoroughly cleaning the surfaces to be welded. The length of the weldingshould be at least twice the width of the G.S. flat, e.g.-minimum 100 mm for 50x6 mm G.S.flat. Exactly similar procedure is to be adopted for joints between two G.S. flats.

b. G.I. wire to structure. The G.I. wire should be bolted to the structure after making an eyeformation and kept tight with the help of spring and ring washer. Then, the entire arrangementshould be welded.

c. G.I. wire to G.S. flat- The G.I. wire should be bolted and then welded to G.S. flat, as explainedabove.

d. G.I. rod to G.S. flat- The G.I. rod should be securely clamped to the G.S. flat with the help ofbolts and washers and the entire arrangement should then be welded.

e. G.I. wire to G.I. pipe – GI wire should be bolted to the G.I. pipe and then welded, keeping inview the relevant precautions, mentioned before.

f. G.I. flat to G.I pipe – The GI flat should be bolted tightly to the G.I. pipe and then theconnection should be welded.

Before making connections and joints, it should be ensured that, the elements to be joinedhave a clean metallic contact surface without any non-conductive coating.

EARTH GRID SYSTEM

Grid system of interconnected conductors forming a closed loop mesh is to be installed using 75x8 mmMS flat for peripheral and branch conductors. Interconnections are made by welding them. This earthgrid will be laid at a depth of about 0.5 mtr. bonded to general mass of the earth by 3 mtrs. long earthelectrode of solid MS rod (or pipe) of dia 25mm. The G.I. pipe 40 mm. dia 3 mtrs. long in the earthingpits, driven vertically.


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It is to this earth grid that the transformer neutral, apparatus, frame work and other non-currentcarrying metal work associated like transformer tank, switchgear frame etc. are to be connected. Allthese connections should be made in such a way that reliable and good electrical connection is ensured.Aluminum/ other paint, enamel, grease and scale should be removed from the point of contact beforeconnections are made. No part of the ground connection leads should be embedded in concrete.

Arrangement of connection of earth connection shall be as follow:

1. STRUCTURES:

Structures including frames, metal supports within the substation grid at least two legs,preferably diagonally opposite (where more than two legs are provided) on each metalstructure shall be connected to earth grid with GI wire of 4mm dia or 6 mm dia.

2. ISOLATORS/ SWITCHES:

The operating handle shall be connected to earth grid independent of the structure earthing orthrough the steel mounting structure, through 4 mm dia G.I. wire.

3. LIGHTNING ARRESTOR:

The bases of lightning arrestors shall be directly connected to the earth electrodes by 4 or 6SWG G.I. wires as short and as straight as practicable, to ensure minimum impedance.Separate earth leads should be used for L.A. in each phase. In addition there shall be as directconnections as practicable from the earthed side of the lightning arrestors to the frame of theapparatus being protected. Surge counters, could also be inserted in the circuit where lightningincidences are high, but in such cases, the lightning arrestor should be mounted on insulatedbase. Invariably, earth connections for lightning arrestors should be separate, and in no caseshould they be joined looped or meshed with other conductors. For lightning arrestorsmounted near transformers, earthing connections shall be done with the earthing pits andearthing leads shall be laid clear of the tank and collars in order to avoid possible oil leakagecaused by arcing. The earth connection should not pass through iron pipes, as it wouldincrease the reactive impedance of the connection.

4. POWER TRANSFORMER:

The tank of the transformer shall be directly connected to the main earth grid. In addition thereshall be a separate and as direct a connection as practicable from the tank to the earth side ofprotecting LA using 4 or 6 SWG GI wire.

The earthing of the neutral shall be by two separate, distinct and direct connections of 50x6 mmGS flat to earth pits, which form a part of the earth grid, and shall be run clear of the tank andcollars.

The transformer track rails shall be connected to earth

5. OUT DOOR VCB:

At least two legs, preferably diagonally opposite of the supporting structure frame work of eachcircuit breaker unit shall be connected to the earth grid, through 50x6 mm G.S. flats.


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6. FENCING:

Fencing and gate should be earthed separately.

7. CURRENT TRANSFORMERS / POTENTIAL TRANSFORMERS:

The bases of the current transformers should be directly connected to the earth grid through 4or 6 SWG G.I. wires. The base (neural side) of the P.Ts. should be directly connected to theearth grid through 4 or 6 SWG G.I. wires. Separate earth leads should be used for P.Ts. ineach phase. The termination of leads on the P.T. neutral should be bolted/clamped and notwelded, to facilitate opening of the earth connection for testing purposes. In addition, allbolted cover plates to which bushings are attached, should be connected to the earth grid,both in case of C.Ts. and P.Ts.

8. Armoring of armored metal-sheathed cables within the station grid area shall be connected tothe earth grid.

9. Substation L.T. Supply Transformer: Same as above except that the neutral earthing conductorused shall be 4 or 6 SWG G.I. wire.


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10. Gi Earthing Pipe

Earthing pipe should be made of 40 mm diameter ISI marked B class GI Pipe. 12 mm dia suitable holeson its circumference shall be made as per approved drawing. The pipe should be in one piece. No jointsor welding would be allowed on its length. Clamps made of 50x6mm GI flat duly drilled with 12 mm sizeholes should be welded at the top end for connection of earth conductor.

Pipe used shall be 40mm NB diameter, ISI marked Galvanized Mild Steel Tubes continuously weldedElectric Resistance Welded ERW/High Frequency Induction welded (HFIW)/Hot finished welded (HFW)type, conforming to IS-554-1985 with latest amendment of MEDIUM quality (Class B).

1. MANUFACTURE:

GI earth pipe (40 mm diameter & 3 metre long) shall be made of tubes which shall be made fromtested quality steel manufactured by any approved process as follows:

a) Electric Resistance Welded (ERW).b) High Frequency Induction Welded (HFIW) andc) Hot finished Welded (HFW).

Tubes made by manual welding are not acceptable.

2. DIMENSIONS:

The dimensions and weights of tubes shall be in accordance with Table-I and Table-II of IS: 1239 (Part-I)/1990 with latest amendments, subject to tolerance permitted therein. Necessary 12 mm diameterholes across the circumference shall be provided as per approved drawing. Drawings shall be approvedby the owner before start of the manufacturing work. The tube, earthing pipe shall be provided with50x6mm GS clamps on one end, one clamp is to be welded with the pipe and another is removable toenable measurement of earth resistance of the pit. Other end of the earth pipe should be cut half inslop to make it a sharp.

3. GALVANIZING:

Tubes shall be galvanized in accordance with IS-4736-1986 with latest amendment for not dip zinccoating of Mild Steel Tubes. The minimum mass of zinc coating on the tubes shall be in accordance withclause 5.1 of IS-4736-1986 (specification for hot dip zinc) and when determined on a 100mm long testpiece in accordance with IS: 6745:1972 shall be 400 g/m2. The zinc coating shall be uniform adherentreasonably smooth and free from such imperfections as flux, ash and dross inclusions, bare patches,black spots, pimples, lumpiness, rust, stains, bulky white deposits and blisters.

4. HYDRAULIC TEST:

(Before applying holes) Each tube shall withstand a test pressure of 5 M Pa maintained for at least 3seconds without showing defects of any kind. The pressure shall be applied by approved means andmaintained sufficiently long for proof and inspection. The testing apparatus shall be fitted with anaccurate pressure indicator

5. TEST ON FINISHED TUBES AND SOCKETS:

The following tests shall be conducted by the manufacturer of finished tubes and sockets.


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a) The tensile strength of length of strip cut from selected tubes when tested in accordance with IS-1894-1972, (Method for tensile testing of steel tubes), shall be at least 320N/mm2.

b) The elongation percentage on a gauge length of 5.65/so (where so is the original cross-sectionalarea of test specimen) shall not be less than 20%.

c) When tested in accordance with IS-2329-1985 (Method for Bend test on Metallic tubes) the finishedtube shall be capable of with standing the bend test without showing any sign of fracture or failure.Welded tubes shall be bent with the weld at 90 degree to the plane of bending. The tubes shall notbe filled for this test.

d) Galvanized tubes shall be capable of being bent cold without cracking of the steel, through 90degree round a former having a radius at the bottom of the groove equal to 8 times the outsidediameter of tube.

e) Flattening Test on Tubes above 50 mm Nominal Bore: Rings not less than 40 mm in length cutfrom the ends of selected tubes shall be flattered between parallel plates with the weld, if any, at90 degree (point of maximum bending) in accordance with IS-2328-1983. No opening should occurby fracture in the weld unless the distance between the plate is less than 75 percent of the originaloutside diameter of the pipe and no cracks or breaks in the metal elsewhere than in the weld shalloccur, unless the distance between the plates is less than 60% of the original outside diameter.The test rings may have the inner and outer edges rounded.

f) GALVANISHING TEST:

Weight of zinc Coating: For tubes thickness upto 6 mm the minimum weight of zinc coating,when determined on a 100 mm long test piece in accordance with IS-4736-1986 shall be 400grm/m2.

The weight of the coating expressed in gram/m2 shall be calculated by dividing the total weightof the zinc (inside plus outside) by the total area (inside plus outside) of the coated surface.

Test specimen for this test shall be cut approximately 100 mm in length from opposite ends ofthe length of tubes selected for testing. Before cutting the test specimen, 50 mm from bothends of the samples shall be discarded.

g) Free Bore Test: A rod 230mm long and of appropriate diameter shall be passed through relevantnominal bore of the sample tubes to ensure a free bore.

h) Uniformity of Galvanized Coating: The galvanized coating when determined on a 100 mm long testpiece [see V (a) (iii)] in accordance with IS-2633-1986 (Method for testing uniformity of coating onzinc coated articles) shall with stand 4 one minute dips.

6. WORKMANSHIP:

The tubes shall be cleanly finished and reasonably free from injurious defects. They shall be reasonablystraight, free from cracks, surface flaws, laminations, and other defects, both internally and externally.The screw tubes and sockets shall be clean and well-cut. The ends shall be cut cleanly and square withthe axis of tube.


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7. MARKING:

The medium class of tubes shall be distinguished by Blue colour bands which shall be applied before thetubes leaves the manufacturers’ works. Tubes shall be marked with the standard mark.

11. Clamps & Connectors

CLAMPS & CONNECTORS: Clamps & connectors shall conform to IS: 5561. The clamps and connectorsshall be made of materials listed below:

For connecting ACSR conductors Aluminium alloy casting, conforming to designationA6 of IS: 617 and shall be tested for all testsas per IS: 617

For connecting equipment terminals made ofcopper with ACSR conductor

Bimetallic connectors made from aluminium alloycasting conforming to designation A6 ofIS:617 with 2mm thick Bimetallic liner andshall be tested as per IS:617

For connecting GS shield wire Galvanised mild steel

Bolts, Nuts & plain washers Hot dip galvanised mild steel for sizes M12 andabove, and electro-galvanised for sizesbelow M12

Spring washers for items ‘a’ to ‘c’ Electro-galvanised mild steel suitable for at

least service condition 4 as per IS:1573

All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and cornersshall be blurred and rounded off.

No current carrying part of a clamp or connector shall be less than 10 mm thick. They shall be designedand manufactured to have minimum contact resistance.

For Bimetallic clamps or connectors, copper alloy liner of minimum 2 mm thickness shall be provided.

Flexible connectors, braids or laminated strips made up of copper/ aluminium for the terminal clamps forequipment shall be suitable for both expansion or through (fixed/ sliding) type connection of IPSAluminium tube as required. In both the cases the clamp height (top of the mounting pad to center line ofthe tube) should be same.

Size of the terminal/conductor for which the clamp/connector is suitable shall be embossed/punched (i.e.indelibly marked) on each components of the clamp/ connector, except on the hardware.

Clamp shall be designed to carry the same current as the conductor and the temperature rise shall beequal or less than that of the conductor at the specified ambient temperature. The rated current for whichthe clamp/ connector is designed with respect to the specified reference ambient temperature, shall alsobe indelibly marked on each component of the clamp/connector, except on the hardware.

Clamps and connector shall be designed corona controlled.

Clamps & connectors shall conform to type tests and shall be subjected to routine and acceptance tests onminimum 3 samples per lot as per IS: 5561. Type tests report for all clamps and connectors fortemperature rise test, tensile test, shall be furnished by the Contractor.


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12. Wiring

All wiring shall be carried out with 1100 V grade stranded copper wires. The minimum size of thestranded conductor used for internal wiring shall be as follows:

1. All circuits except CT circuits 2.5 sq.mm2. CT circuits 2.5 sq. mm (minimum number of strands shall be 3 per conductor).

All internal wiring shall be securely supported, neatly arranged readily accessible and connected toequipment terminals and terminal blocks.

Wire terminations shall be made with solderless crimping type of tinned copper lugs which firmly gripthe conductor and insulation. Insulated sleeves shall be provided at all the wire terminations. Engravedcore identification plastic ferrules marked to correspond with the wiring diagram shall be fitted at bothends of each wire. Ferrules shall fit tightly on the wires shall not fall off when the wires and shall not falloff when the wire is disconnected from terminal blocks.

All wires directly connected to trip circuit breaker shall be distinguished by the addition of a red colouredunlettered ferrule. Number 6 & 9 shall not be included for ferrules purposes.

All terminals including spare terminals of auxiliary equipment shall be wired upto terminal blocks. Eachequipment shall have its own central control cabinet in which all contacts including spare contacts fromall poles shall be wired out. Inter-pole cabling for all equipment’s shall be carried out by the Contractor.


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13. Equipment Erection Notes

All support insulators, circuit breaker and other fragile equipment shall preferably be handled withcranes with suitable booms and handling capacity.

The slings shall be of sufficient length to avoid any damage to insulator due to excessive swing,scratching by sling ropes etc.

For cleaning the inside and outside of Hollow insulators only muslin of leather cloth shall be used.

Handling equipment, sling ropes etc. should be tested before erection and periodically for strength.

Bending of compressed air piping should be done by a bending machine and through clod bending only.Bending shall be such that inner diameter of pipe is not reduced.

Cutting of the pipes wherever required shall be such as to avoid flaring of the ends, and only a properpipe cutting tool shall be used. Hack-saw shall not be used.

The Contractor shall arrange at site all the equipments, instruments and auxiliaries required for testingand commissioning of equipment.

STORAGE OF EQUIPMENTS

The Contractor shall provide and construct adequate storage shed for proper storage of equipments.Weather sensitive equipment shall be stored indoor. All equipments during storage shall be protectedagainst damage due to acts of nature or accidents. The storage instruction of the equipmentmanufacturer/Owner shall be strictly adhered to.


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14. Danger Notice Plates

1. SCOPE

This Specification covers Danger Notice Plates to be displayed in accordance with rule No. 35 of IndianElectricity Rules, 2003.


Unless otherwise modified in this specification, the Danger Notice Plates shall comply with IS:2551-

1982 or the latest version thereof.

3. DIMENSIONS

3.1 Two sizes of Danger Notice Plates as follows are recommended:

a) For display at 415 V installations - 200x150mm

b) For display at 11 KV (or higher voltages) installations - 250x200mm

3.2 The corners of the plate shall be rounded off.

3.3 The location of fixing holes as shown in Figs. 1 to 4 is provisional and can be modified to suitthe requirements of the purchaser.

4. LETTERINGS

All letterings shall be centrally spaced. The dimensions of the letters, figures and their respectiveposition shall be as shown in figs. 1 to 4. The size of letters in the words in each language and spacingbetween them shall be so chosen that these are uniformly written in the space earmarked for them.

5. LANGUAGES

5.1 Under Rule No. 35 of Indian Electricity Rules, 2003, the owner of every medium, high and extra highvoltage installation is required to affix permanently in a conspicuous position a danger notice in Hindi orEnglish and, in addition, in the local language, with the sign of skull and bones.

5.2 The type and size of lettering to be done in Hindi is indicated in the specimen danger notice platesshown in Fig. 2 and 4 and those in English are shown in Figs. 1 and 3.

5.3 Adequate space has been provided in the specimen danger notice plates for having the letterings inlocal language for the equivalent of' Danger',' 415' '11000' and 'Volts'.

6. MATERIAL AND FINISH

The plate shall be made from mild steel sheet of at least 1.6mm thick and vitreous enameled white,with letters, figures and the conventional skull and cross-bones in signal red colour (refer IS:5-1978) onthe front side. The rear side of the plate shall also be enamelled.


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7. TESTS

The following tests shall be carried out :

i) Visual examination as per IS:2551-1982

ii) Dimensional check as per IS:2551-1982

iii) Test for weather proofness as per IS:8709-1977 (or its latest version)

8. MARKING

Maker's name and trade mark and the purchaser's name shall be marked in such a manner and positionon the plates that it does not interfere with the other information.

9. PACKING

The plates shall be packed in wooden crates suitable for rough handling and acceptable for rail/roadtransport.


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15. Number Plate (Support)

Weather proof number plate shall have unique name are to be installed on the pole support. The plateshall be made from mild steel sheet of at least 1.6mm thick and vitreous enameled white, with letters insignal red color (refer IS: 5-1978) on the front side. The rear side of the plate shall also be enameled.The digits shall be as under:

110121

000001

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Digits shall be displayed as detailed above having at-least 25mm height. The over all size of the plateshall be 200x250mmx1.6mm. The corners of the plate shall be rounded off. All lettering shall becentrally spaced. The dimensions of the letters, figures and their respective position shall be as shownabove. The size of digits and spacing between them shall be so chosen that these are uniformly writtenin the space earmarked for them. The type and size of digits to be written in English as indicated above.The plate should be provided with 6mm dia holes in horizontal alignment for fixing to the pole by meansof Galvanized MS flat clamp of 25x3 mm size. The nut & bolts used for fixing of plate should be ofgalvanized and washers of electro-plated. The bolt should be used of at-least 6mm diameter.

TESTS: The following tests shall be carried out:

i) Visual examination as per IS:2551-1982ii) Dimensional check as per IS:2551-1982iii) Test for weather proof-ness as per IS 8709-1977 (or its latest version).

Numbering Transformer/ Feeders/ Equipments ( in Grid Sub-Station ):

All augmented/ new power transformer, Breakers, Outgoing feeders,respective control panels, Kiosksare to be named. Base should be painted with yellow paint and black digits should be displayed of at-least 25mm height. Experienced painter should be used to provide this work. LT and HT bushing shouldbe colour coded, CT and PT panels are to be named. The Yellow base plate should be encircled by ablack strip. Naming shall be in the local as well as English language.

Numbering of control panel:

Name of Feeder should be displayed on front end and at rear end along with serial number of thepanel. Yellow base paint and 25mm high black digits are to be used for this purpose. The base paintshould be encircled by a black strip. Naming shall be in the local as well as English language.


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Strip

25mm Height


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16. Cable Glands and Lugs

Cable glands shall be Double compression type, tinned/Nickel plated (coating thickness not less than 20microns in case of tin and 10 to 15 microns in case of nickel) brass cable glands for all power andcontrol cables. They shall provide dust and weather proof terminations. They shall comprise of heavyduty brass casting, machine finished and tinned to avoid corrosion and oxidation. Rubber componentsused in cable glands shall be neoprene and of tested quality. Required number of packing glands toclose unused openings in gland plates shall also be provided.

The cable glands shall be tested as per BS: 6121. The cable glands shall also be duly tested for dustproof and weather proof termination.

Cables lugs shall be tinned copper solder less crimping type conforming to IS: 8309 and 8394 suitablefor aluminum or copper conductor (as applicable). The cable lugs shall suit the type of terminalsprovided. The cable lugs shall be of Dowell make or equivalent.


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17. Cables Tags and Markers

Each cable and conduit run shall be tagged with numbers that appear in the cables and conduitschedule.

The tag shall be of aluminum with the number punched on it and securely attached to the cable conduitby not less than two turns of 20 SWG GI wire conforming to IS: 280. Cable tags shall be of rectangularshape for power cables and of circular shape for control cables.

Location of cables laid directly underground shall be clearly indicated with cable marker made ofgalvanized iron plate.

Location of underground cable joints shall be indicated with cable marker with an additional inscription“Cable Joint”.

The marker shall project 150 mm above ground and shall be spaced at analysis interval 30 meters andat every change in direction. They shall also be located on both sides of road and drain crossings.

Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure),on both sides of a wall or floor crossing and on each duct/ conduit entry. Cable tags shall be providedinside the switchgear, motor control centers, control and relay panels, etc., wherever required for cableidentification, such as where a number of cables enter together through a gland plate.

The price of cable tags and markers shall be included in the installation rates for cables/ conduitsquoted by the contractor.

Specific requirements for cabling for cabling, wiring, ferrules as covered in respective equipment sectionshall also be complied with.

CABLE GLANDS

Double compression type cable glands shall be provided by the Contractor for all power and controlcables to provide dust and weather proof termination. Required number of packing glands to closeunused openings in gland plates shall also be provided.

CABLE LUGS

Solderless crimping of terminals shall be done by using corrosion inhibitory compound. The cable lugsshall suit the type of terminals provided. Crimping tool used shall be of approved design and make.

Storage and handling of cable drums

Cable drums shall be unloaded, handled and stored in an approved manner. Rolling of drums shall beavoided as far as practicable. For short distances, the drums may be rolled provided they are rolledslowly and in proper direction as marked on the drum. In absence of any indication the drums may berolled in the same direction it was rolled during taking up the cables.

CABLE SUPPORTS AND CABLE TRAY MOUNTING ARRANGEMENTS

Cable trenches in the control room are normally provided with embedded steel inserts on concretefloors/ walls. The Contractor shall secure supports by welding to these inserts or available building steelstructures.

Insert plates will be provided at an interval of 600 mm wherever cables are to be supported without theuse of cable trays, while at all other places these will be at an interval of 2000 mm.


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CABLE TERMINATIONS AND CONNECTIONS

The termination and connection of cables shall be done strictly in accordance with cable and terminationkit manufacturer’s instructions, drawing and/ or as directed by the Owner.

The work shall include all clamping, fittings, fixing, plumbing, soldering, drilling, cutting, taping, heatshrinking (where applicable), connecting to cable terminal, shorting and grounding as required tocomplete the job.

The equipment will be generally provided with un-drilled gland plates for cables/ conduit entry. TheContractor shall be responsible for drilling of gland plates, painting, and touching up. Holes shall not bemade by gas cutting.

The Contractor shall tag/ferrule the control cable cores at all terminations, as instructed by the Owner.In panels where a large number of cables are to be terminated and cable identification may be difficult,each core ferrule may include the complete cable number as well. Spare cores shall be similarly taggedwith cable numbers and coiled up.

Control cables shall have stranded copper conductor. Bare portion of the solid conductors shall betinned after removing the insulation and shall be terminated directly without using cable lugs.

All cable entry points shall be sealed and made vermin and dust proof. Unused openings shall beeffectively closed.

If the cable-end box or terminal enclosure provided on the equipment is found unsuitable and requiresmodification, the same shall be carried out by the Contractor with the approval of the Owner.

DIRECTLY BURIED CABLES

The Contractor shall construct the cable trenches required for directly buried cables. The scope of workand unit rates for construction of cable trenches for cables shall include excavation, preparation of sandbedding, soil cover, supply and installation of brick or concrete protective cover, back filling andreaming, supply and installation of route markers and joint markers. The Contractor/Supplier shallascertain the soil conditions prevailing at site, before quoting the unit rates. Laying the cable andproviding protective covering shall be as per approved drawing.

Installation of cables

Power and control cables shall be laid in separate tiers. The order of laying of various cables shall be asfollows:

Power cables on top tiers. Control, instrumentation and other service cables in bottom tiers.

Single core cable in trefoil formation shall be laid with a distance of three times the diameter of cablesbetween trefoil center lines. All power cables shall be laid with a minimum center to center distanceequal to twice the diameter of the cable.

Power and control cables shall be securely fixed to the trays/ supports. Trefoil clamps for single corecables shall be pressure die-cast aluminum (LM-6). Nylon-6 or fiber glass and shall include necessaryfixing nuts. bolts, washer, etc. These are required at every 2 meter of cable run. Vertical and inclinedcable runs shall be secured with 25 mm wide and 2 mm thick aluminum strip clamps at every 2 mHorizontal runs in cable trays and trenches shall be secured using 4 mm nylon cord at every 2 m.


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Cables shall not be bent below the minimum permissible limit. The minimum bending radius of powercables shall be 12D and that of control cables shall be 10D, where D is overall diameter of cable.

Where cables cross roads, drains and rail tracks, the cables shall be laid in reinforced spun concrete orsteel pipes, buried at not less than one meter depth.

In each cable run some extra length shall be kept at a suitable point to enable one (for LT Cables) ortwo (for H.T. cables) straight through joints to be made, should the cable develop fault at a later date.

Selection of cable drums for each run shall be so planned as to avoid using straight through joints.Cable splices will not be permitted except where called for by the drawings, unavoidable or wherepermitted by the Owner.

Control cable terminations inside equipment enclosures shall have sufficient lengths so that switching oftermination in terminal blocks can be done without requiring any splicing.

Metal screen and armour of the cable shall be bonded to the earthing system of the station, whereverrequired.

Rollers shall be used at intervals of about 2.0 meters, while pulling cables.

All due care shall be taken during unreeling, laying and termination of cable to avoid damage due totwist, kink, sharp bends, etc.

Cable ends shall be kept sealed to prevent damage.

Inspection on receipt, unloading and handling of cables shall generally be in accordance with IS:1255and other Indian Standard codes or practices.

Wherever cables pass through floor or through wall openings or other partitions, wall sleeves withbushes having a smooth curved internal surface so as not to damage the cables shall be supplied,installed and properly sealed at no extra charges.

The erection work shall be carried out in a neat workmanlike manner and the areas of work shall becleaned of all scrap materials after the completion of work in each area every day. Contractor shallremove the RCC/steel trench covers before taking up the work and shall replace all the trench coversafter the erection work in that particular area is completed or when further work is not likely to be takenup for some time.

Contractor shall furnish three copies of the report on work carried out in a particular week, such ascable numbers and a date on which laid, actual length and route, testing carried out, terminationscarried out, along with the marked up copy of the cable schedule and interconnection drawing whereverthe modifications are made.

In case the outer sheath of a cable is damaged during handling/ installation, the Contractor shall repairit at his own cost, and to the satisfaction of the Engineer-in- Charge. In case any other part of a cable isdamaged, the same shall be replaced by a healthy cable, at no extra cost i.e. the Contractor shall notbe paid for supply, installation and removal of the damaged cable.

All cable terminations shall be appropriately tightened to ensure secure and reliable connections. TheContractor shall cover the exposed part of all cable lugs whether supplied by him or not with insulatingtype, sleeve or paint.


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18. GI Wires

1. SCOPE

This specification covers details of solid G.I. Wires for use in rural distribution system.


Except when they conflict with the specific requirements of this specification, the G.I. wires shallcomply with the provisions of IS:280-1978 and IS:7887-1975 or the latest version thereof.

3. APPLICATION & SIZES

G.I. wires covered in this Specification are intended for thefollowing applications :

Application Sizes (nominal dia)

Bearer wire for service3.15mm (for single phase cables services ) 4

mm ( for three phase services)

Earthing of Transformers, poles & Fittings. 4 mm

Continuous Earthwire for. 11 KV lines 4 mm

Protective guarding at the crossing ofover-head power lines with roads,

railway tracts andtelecommunication lines

3.15, 4 and 5 mm

4. MATERIAL

4.1 The wires shall be drawn from the wire rods conforming to IS:7887-1975 or the latest versionthereof.

4.2 The requirements for chemical composition for the wires shall conform to IS:7887.

4.3 The wires shall be sound, free from split surface flaws, rough jagged and imperfect edges andother detrimental defects on the surface of the wires.

5. GALVANISING

The wires shall be galvanised with ‘Heavy Coating’ as per IS:4826-1979 or the latest versionthereof.

6. GRADES

GI wires shall be classified into two grades based on their tensile strength :

GradeTensile Strength

(MPa)

Annealed 300-550

Hard 550-900


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7. TOLERANCE IN DIAMETER

The tolerance on nominal diameter at any section of wire shall not exceed (±)2.5%. Further,the maximum difference between the diameters at any two cross-sections of wires shall notexceed 2.5%.

8. TESTS

The following tests shall be carried out in accordance with IS:280-1978 or the latest versionthereof as per sampling criteria stipulated therein :

i) Dimensional check (dia) - refer clause 7 above.

ii) Visual inspection regarding freedom from defects refer clause 4.3 above.

iii) Tensile test

iv) Wrapping test (for wire diameters smaller than 5mm)

v) Bend test (for wire diameters 5mm only)

vi) Coating test - refer clause 5 above

vii) Chemical composition

9. PACKING

The wires shall be supplied in 50-70 kg. coils, each coil having single continuous length. Eachcoil of wire shall be suitably bound and fastened compactly and shall be protected by suitablewrapping.

10. MARKING

Each coil shall be provided with a label fixed firmly on the inner part of the coil bearing thefollowing information :

a) Manufacturer’s name or trade mark

b) Lot number and coil number

c) Size

d) Grade (Annealed or Hard)

e) Mass

f) Length

g) ISI Certification mark, if any

VOLUME-III: SECTION - I (A)

CATEGORY A METER SPECIFICATION

Type of meter -HT Feeder meter

Input Voltage -3 x 110 volt phase to phase

Input Current -1A / 5A

Burden Type /Phase -1.5 Watts/phase or 10 VA/phase for voltage circuit and 1 VA phase for eachcurrent circuit

3 phase 4 wire

Starting Current -0.1 % of basic

Accuracy -0.5

Type of meter 3-phase DT meter

Input Voltage -433±20% phase to phase

Input Current -5A

Burden Type /Phase -1.5 Watts/phase or 10 VA/phase for voltage circuit and 1 VA phase for eachcurrent circuit

Starting Current -0.1 % of basic

Accuracy -0.5

Type of meter : 1-phase DT meter

Input Voltage :240+20% -30% phase to neutral

Input Current :5A

Burden Type /Phase :1.5 Watts/phase or 10 VA/phase for voltage circuit and 1 VA phase for each

Starting Current :0.1 % of basic

Accuracy : 0.5

3 PHASE 4 WIRE 0.5 CLASS ENERGY METER FOR FEEDER (DLMS Compliant category A meters)

2.1 GENERAL & CONSTRUCTIONAL REQUIREMENTS

2.1.1 Meters shall be designed and constructed in such a way so as to avoid causing any dangerduring use and under normal conditions. However, the following should be ensured :

a) Personal safety against electric shock.

b) Personal safety against effects of excessive temperature.

c) Protection against spread of fire.

d) Protection against penetration of solid objects, dust & water.

e) Detection against fraud.

f) Detection against pilferage.

2.1.2 The meter shall be designed with application specific integrated circuit and shall bemanufactured using SMT (Surface Mount Technology). Power supply and voltage divider circuitsmay be of PTH technology. The meter should be housed in a safe, high grade engineering plastic /polycarbonate casing, which is of projection mounting type and is dust/moisture proof, conformingto IP-51 of BIS 12063 / IEC 529.

2.1.3 All insulating material used in the construction of meters shall be non-hygroscopic, non-ageingand of tested quality. All parts that are likely to develop corrosion shall be effectively protectedagainst corrosion during operating life by providing suitable protective coating.

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2.1.4 The meter shall be supplied with a transparent extended terminal block cover (ETBC). Themeter base, meter cover, terminal block and ETBC shall be made of unbreakable high grade fireresistant non-flammable reinforced, polycarbonate (not bakelite) or equivalent high gradeengineering plastic, which should form an extension of meter cases and have terminal holes andshall be of sufficient size to accommodate insulation of the conductors, meeting the requirement ofCBIP technical report CBIP.88.

2.1.5 The extended terminal block cover should be separately sealable at two places and housed atthe bottom of the meters and once sealed should prevent unauthorized tampering.

2.1.6 The terminal block should have sufficient insulating properties, mechanical strength and shouldhave tin plated solid brass terminals with two fixing screws per terminal. The terminals should bedesigned to withstand high overload.

2.1.7 The meter should not get damaged or substantially influenced by the electromagneticdisturbances and electrostatic discharges caused by harmonics, voltage dips and short interruptions,transients, DC and AC magnetic field.

2.1.8 The meter shall have an operation indication device such as a blinking LED/ LCD. The operationindicator shall be visible from the front window and capable of being monitored conveniently withsuitable testing equipment.

2.1.9 The meter shall conform to the degree of protection IP 51 but without suction in the meter asper IS: 12063/IEC: 529 for protection against ingress of dust, moisture and vermin.

2.1.10 The meter-base, meter cover, terminal block and ETBC shall be made of unbreakable, highgrade, fire resistant, reinforced, non-flammable, polycarbonate or equivalent high grade and goodquality engineering plastic.

2.1.11 The terminal block, the ETBC and the meter case shall ensure reasonable safety against thespread of fire. They should not be ignited by thermic overload of live parts in contact with them.

2.1.12 The meter shall have Zn plated MS/Nickel plated Brass terminals. The terminals shall havesuitable construction with barriers and cover to provide firm and safe connection of current andvoltage leads of stranded copper conductors or copper reducer type terminal ends (thimbles).

2.1.13 The manner of fixing the conductors to the terminal block shall ensure adequate and durablecontact such that there is no risk of loosening or undue heating. Screw connections transmittingcontact force and screw fixing which may

be loosened and tightened several times during the life of the meter shall be such that the risk ofcorrosion resulting

from contact with any other metal part is minimized. Electrical connections shall be so designed thatcontact

pressure is not transmitted through insulating material. The internal diameter of the terminal holesshall be 5.0 mm

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minimum. The clearance and creepage distance shall conform to relevant clause of IS14697:1999/CBIP technical

report No. 88.

2.1.14 The meter shall be compact in design. The entire and construction shall be capable ofwithstanding stresses likely to occur in actual service and rough handling during transportation. Themeter shall be convenient to transport and immune to shock and vibration during transportationand handling.

2.1.15 The meter shall have a design to operate satisfactory for 10 years under normal electricalcondition and guaranteed life of 18 months from the date of commissioning against manufacturingand design defects. The meters found defective with in guaranteed period shall be replaced bymanufacturer free of cost within one month of intimation.

2.1.16 The meter shall be provided with accurate quartz crystal based real time clock and calendarwith the accuracy limit as per relevant standards. Meter shall have provision to synchronise themeter time with standard time through CMRI with proper security system.

2.1.17 The integration period shall be set as 30 minutes and subsequently can be changed on real-time basis.

2.1.18 Vendor will give one copy of all the software’s (meter reading software for CMRI, software foruploading data from CMRI to computer).

2.1.19 It should be possible to check the healthiness of phase voltages by displaying all the voltageson the meter display.

2.1.20 The Meter should have battery backup to be read in absence of Power Supply. It should be aseparate internal battery other than RTC battery.


2.1.22 The meter should remain powered up and functional even when either any two phases areavailable to the meter.

2.1.23 The meter shall record active energy, even if one or more CT”s are reversed. The currentvector direction shall always be considered as positive (import) for computation of energy and shallbe added in main active energy register.

2.1.24 Data Security: The Meter shall have multilevel password for data protection and security. Themeter data retrieval shall be possible through authenticated CMRI. The meter shall support theevent of change of TOD register timings / no. of TOD registers, demand integration period and /orsetting the meter time through authenticated transaction and shall be logged as an event. Thetransaction events shall be available for viewing at BCS end.

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2.1.25 The meter data shall be retrievable through CMRI and will be downloaded in the Basecomputer software for viewing, analysing and printing. The meter data downloaded at BCS endshould be in user-friendly formats. The manufacturer shall supply the required software for basecomputer system. The base computer software shall have the facility to convert the required data(For billing, Energy Audit, tamper analysis purpose) in to ASCII format. This data should be possibleto be used as input data for any other software to generate desired reports as per the utilityrequirement.

2.1.26 The meter shall have radio interference suppression such that it should not generate noise,which could interfere with the other equipment.

2.1.27 The meter shall have three fixing holes, one at the top and two at the bottom. The top holeshall be provided with a special clip at the back of the meter so that holding screw is not accessibleto the consumer after fixing the meters. The lower fixing screws shall be provided under the sealedterminal cover. The requisite fixing screws shall be supplied with each meter.


Reliable sealing arrangement should be provided to make the meter tamper proof and avoidfiddling or tampering by unauthorized persons. For this, at least two no. of seals on meter body, twono. of seals on meter terminal cover and one no. of seal on each communication port shall beprovided. All the seals shall be provided in front side only. Please refer Annexure A for specificationfor sealing system. The meter cover and base should be ultrasonically/chemically welded on atleastthree sides of the meter so that if the meter cover is opened there is clear evidence of tamperingand the meter should be completely broken.

2.3 CONNECTION DIAGRAM & TERMINAL MARKINGS

The terminals shall be marked properly on terminal block for giving external connections. Adiagram of connections should be provided inside the cover of terminal block. The terminal covershall be extended such that when it is placed in position it is not possible to approach theconnections or connecting wires. The terminals and the screws shall be suitable to carry upto 150%

of Imax safely. The terminals shall have suitable construction with barriers and covers to providesecure and safe connections.

2.4 REMOTE READOUT FACILITY, COMMUNICATION CAPABILITY

The meter also shall have a separate individually sealable RS-485 communication port tocommunicate with Remote Terminal Unit (RTU) over Modbus protocol in multi-drop mode so thatselected analog data can be communicated to central location for SCADA / DMS application. Theimplementation detail of MODBUS protocol shall be furnished by the bidder.

2.5 SOFTWARE

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Licensed copies of the software (meter reading software for CMRI, software fordownloading/uploading data from CMRI to computer) shall be made available and shall be installedon each common meter reading instrument (CMRI) and Base computer by the manufacturer.

Common Meter Reading Instrument (CMRI) would be loaded with user-friendly software (MS-DOS5.0 or higher version compatible) for reading, downloading meter data and Time of Day (TOD)programming in the meter.

Windows based user interactive Software for receiving data from CMRI and downloadinginstructions from base computer to CMRI. This software should have, amongst other requirements,features and facilities as described later in this specification, the facility to convert meter readingdata into a user definable DBF (Access) or spreadsheet orASCIIformat or any other format forintegrating with the Employer's billing system as desired/required by the utility. Here again an"Export wizard" or similar utility shall be available whereby user can select file format, the variabledata to export, the field width selection of each variable so that it may be possible for the user tointegrate the same with the user’s billing data and process the selected data in desired manner.

The software shall have the flexibility to generate the following sets of reports :

x Load survey reports x Tamper reports

Necessary software for loading application program into meter via CMRI serial port shall also beprovided.

The BCS should incorporate the following points:-

1. Line graph should be provided in load survey of the BCS

2. There should be provision for daily, weekly and monthly viewing of meter DATA.

3. There should be provision for meter serial number/date wise viewing of meter DATA.

4. The load survey should be consist of voltage, energy, maximum demand and power factor. Theseparameters should be on selectable basis.

5. In the bar graph of the load survey in BCS, the thirty minutes maximum demand integrationperiod should have accurate values up to the last three decimal point.

6. All temper should be logged properly with date and time.

7. Maximum demand values and other parameters in the load survey of the BCS should be loggedand visible properly with date and time on pointing of the cursor on the graph.

8. BCS should be operable through single window and user friendly

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2.5.1 Tamper reports to include for a pre-determined duration or month wise, tamper count, tamperduration and tamper history for each of the meters.

2.5.2 There should be provision to synchronize RTC (Real Time Clock) of the meter throughCMRI/BCS and it should be password protected.

2.5.3 Vendor will provide soft copy of all the software in CD form along with the meters supplied.

2.5.4 Vendor to install & demonstrate working of software programmes of other metermanufacturers on the CMRI’s to be supplied with this package.

The specification of CMRI are presented as Annexure B.

2.6 DISPLAY

A real time quartz clock shall be used in the meter for maintaining time and calendar date. Themaximum drift shall not exceed 5 minutes per year. The uncertainty of setting initial time shall notexceed + 30 Seconds with respect to Indian standard time (Ref NPL New Delhi).

Facility for adjustment of real time shall be provided through CMRI with proper security.

The meter shall have a minimum 7 digits, 7segment display of liquid crystal display (LCD) or lightemission diode display (LED) with another digit for legend. The minimum character height shall be10 mm. Provision shall be made to read consumption in either whole units or decimal multiples orsub-multiples of one possible to display content of relevant parameters with another digit displayinglegend for identification.

The display shall remain on the screen till operator presses button for subsequent display or 10 secwhich ever is earlier.

The meter should have non-volatile memory, so that the registered parameters will not be affectedby loss of power. A provision shall be made to read the meter parameters such as MD andconsumption, etc., through the meter cover without actually opening the meter box cover. The non-volatile memory should have a minimum retention time of 10 years under unpowered condition.

2.7 DISPLAY SEQUENCE

The meter shall display the required parameters in two different modes as follows:

A. Auto Display Mode :

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Display test (LCD/LED Segment check)

x Real time & date x Active energy forwarded x Reactive energy lag x Reactive energy lead xApparent energy forwarded x Last bill Active and Apparent Energy x Last bill Maximum Demand inkVA x Average Bill Power Factor x Maximum Demand forwarded x MD occurrence date and time xRising demand with elapsed time x MD reset count x Cumulative MD forwarded x Instantaneousaverage 3 I PF x Instantaneous frequency x Phase voltages R,Y,B x Phase currents R,Y,B x Cumulativepower on hours of current month



x Tamper and fraud details x Present CT status x Last occurrence tamper ID x Date and time of lasttamper occurrence x Last restoration tamper ID x Date and time of last tamper restoration xCumulative tamper count x TOD Register [Active forwarded energy (8 Nos)] x TOD Register[Apparent forwarded energy (8 Nos)] x TOD Register [Apparent forward MD (8 Nos)] x Cumulativepower on hours



x Energy registers x Billing registers

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x TOD Registers x Load survey data x Tamper and fraud (all event details with date and time) x Selfdiagnostic details x Real time calendar clock fail x Battery bad flag x History of monthly Energy Flow,Maximum Demand, Average power factor for the last 12 months


The maximum demand is to be monitored during each demand interval set with 30 minutesintegration and the maximum of these in a month shall be stored. Whenever MD is resent themaximum demand value so registered shall be stored along with date and time. Under the currentintegration period, the rising demand should be displayed continuously along with the elapsed time.The registered demand and the number of times the MD is reset shall also be displayed and theinformation stored.

2.9 MAXIMUM DEMAND RESET

Facility for auto reset of MD at 00.00 hrs of first of every month shall be provided for whichminimum 30 years calendar shall be programmed by the manufacturer.

The meter shall display the maximum demand reset count.

2.10 LOAD SURVEY CAPABILITY

Load survey shall be available for at least 45 days with 30 minutes load survey integration period forfollowing parameters. Vendor shall provide necessary facility to transfer data through CMRI/PublicSwitch Telephone Network-PSTN/Low Power Radio (LPR)/GSM.

a. kWh forwarded b. kVAh forwarded c. kVARh lag d. Voltage Phase wise e. Current Phase wise f.Daily maximum demand active & Apparent.

The load survey data, abnormality event information and instantaneous parameters data shall all beretrievable through the meter's communication port from a common meter reading instrument(CMRI)/ Hand Held Unit and shall be transferred (downloaded) to a PC with user friendly Windowsbased software to get complete details in numerical and/or graphic form. The necessary featureshall be available in the software used for uploading data from CMRI to computer and shall beprovided by the manufacturer with complete details.

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The meter shall have sufficient non-volatile memory for recording history of energy parameters forlast twelve billing cycles (Bill date shall be 00 hrs of the 1st date of the calendar month by default –programmable) and information should be made available at the BCS end.

2.11 TIME-OF-DAY (TOD) TARIFF/DEMAND

The meter should have provision of registering the time-of- day energy and maximum demand. Itshall be possible to define TOD register for active forwarded, apparent forwarded energy type.

The meter should have in-built capacity to define up to eight (8) time zones through operation ofCMRI.The change of the TOD time-period(s) or changing number of TOD zones should be possiblethrough CMRI with special authenticated command from the software used for uploading data fromCMRI to computer so that only authorised person(s) can make such changes. The main control ofthis system along with proper security password/code should be available on one or morecomputers located at the authorised location(s) as per the directions to be given by the Employer.

2.12 SELF DIAGNOSTIC FEATURE

2.12.1 The meter shall be capable of performing complete self diagnostic check to monitor thecircuits for any malfunctioning to ensure integrity of data memory location at all times. The metershall have indications for unsatisfactory/nonfunctioning/malfunctioning of the following:

a) Real Time and Date b) All display segments as per the requirement c) Nonvolatile memory (NVM)failure indication at BCS d) Low battery indication at BCS

2.12.2 While installing the meter, it should be possible to check the correctness of Current andVoltage Transformer connections to the meter and their polarity from the functioning of the meterfor different voltage injections with the help of vector/phasor diagrams. For this purpose a suitablesoftware for field diagnosis of meter connections with the help of Meter Reading Instrument shouldbe supplied.


The meter shall function properly under following common abnormal conditions:

1. Phase sequence reversal The meter shall keep working accurately irrespective of the phasesequence of the supply.

2. Current reversal / CT polarity reversal The meter shall log energy in forward direction even if thecurrent is flowing in reverse direction in one or more phases.

3. External magnetic The metering system shall be provided with adequate magnetic shielding sothat any external magnetic field (AC Electro Magnet or DC Magnet) as per the values

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influence

specified in CBIP Technical Report No.88 (with latest amendments) applied on the metering systemshall not affect the proper functioning and recording of energy as per error limits prescribed by CBIP.

4.35kV spark discharge The meter shall be immune to application of 35kV spark discharge for min 10minutes.

5. Jammer The meter shall be immune to application of high frequency jammer.

Beside this the meter should have features to detect the occurrence and restoration of, at least, thefollowing common abnormal events:

i. Missing Potential & Potential imbalance: The meter shall be capable of detecting and recordingoccurrence and restoration with date and time the cases of Potential failure which could happen dueto disconnection of potential leads (one or two), failure of phase line fuse from the PotentialTransformer primary side. Meter shall also detect and log cases of voltage unbalance (from 5% formore than 5 minutes or more (programmable)) of voltages.

ii. Voltage High / Voltage Low: In case the average 3 phase voltage remains less (below 0.75Vref bydefault) than or above (above 1.15Vref by default) for a predefined period (30 minutes by default),the meter shall log such incidences with date & time. The voltage thresholds & persistence time shallbe programmable using the CMRI &BCS. This abnormal condition shall be logged only when all thethree-phase voltage is available.

iii. Current imbalance: The meter shall be capable of detecting and recording occurrence andrestoration with date and time of Current unbalance (30% or more for more than 15 minutes, or asprogrammable).

iv. Current Circuit Short: The meter shall be capable of detecting and recording occurrences andrestoration of shorting of any one or two phases of current circuit to identify events like CTsaturation, CT lead shorting, CT inter turns short etc.

v. Current Circuit Open: The meter shall be capable of detecting and recording occurrences andrestoration of opening of any one or two phases of current circuit which can happen due to

intentional / accidental disconnection of current circuits. The meter shall be able to log abnormalityconditions in current open event like CT leads burns, loose connection, CT winding open etc in themeter memory. No load condition should not be recorded in meter memory as a Current circuitopen event.

vi. Power on/off: The meter shall be capable to record power on /off events in the meter memory.All potential failure should be recorded as power off event. vii. Cover Open: The meter shall be ableto detect cover open occurrence event if cover is opened in mains on or off condition. Separatelegend for cover open event shall be made available on LCD. This legend shall remain in on state tillmeter reading so that it will come in to notice of meter reader. This tamper should be logged asnon-rollover event.

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The meter shall record the total duration of the above abnormalities, time and date of theiroccurrences & restorations with a snap shot of electrical conditions viz. Voltage , current ,PF etc

Logic for calculation of voltage and current imbalance shall be furnished by the tenderer.

The meter shall keep records for the minimum last 250 events (occurrence + restoration) for aboveof abnormal conditions. It shall be possible to retrieve the abnormal event data along-with allrelated snap- shots' data through the meter's optical port with the help of a hand held unit (HHU)and download the same to the BCS where it shall be available for viewing. All this information shallbe made available in simple and easily understandable forma

2.14 TAMPER LOGIC

Properly designed meter event logic should be provided. There shall be separate compartments forlogging of potential related event, current related event and power on/off event. The bidder shouldexplain the events details in each compartment under their offer. The logging of various events ineach compartment should be as under: Once one or more compartments have become full, the lastevent pertaining to the same compartment will be entered and the earliest (first one)-event shoulddisappear. Thus, in this manner each succeeding event will replace the earliest recorded event,compartment wise. Events of one compartment/category should overwrite the events of their owncompartment/category only. A properly defined meter tamper logic should be provided. Thetamper logic should be capable of discriminating the system abnormalities from source side and loadside and it should not log/record tamper due to source side abnormalities. There shall be threeseparate compartments for logging of different types of tampers as follows: x Compartment No. 1:50 % of the tamper memory space shall be allocated for the following current related tampers - CTopen circuit

- CT short (bypass)

x Compartment No. 2: 25 % of the tamper memory space shall be allocated for missing potentialtampers. x Compartment No. 3: 25 % of the tamper memory space shall be allocated for currentunbalance tampers

2.15 TESTS

Unless specifically waived off all test shall be witnessed by the Employer.

2.15.1 Type Test

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Offered Energy Meters shall be fully type tested as per IS 14697 / CBIP Technical Report No. 88 atany of the NABL accredited test laboratories and type test report shall be provided of not more than2 years old. Also DLMS test certificate as per IS 15959 at any NABL laboratory must be provided.

In case meters are not type tested in NABL accredited test laboratories the bidder shall arrange tocarry out type tests in any of the NABL accredited test laboratories at his own cost.

2.15.2 Acceptance Test

Acceptance test shall be carried out as per IS 14697.

2.15.3 Routine Test

All routine tests as specified in IS 14697. 2.16 FIXING OF METERS

The meters shall be mounted in the panels.

2.17 OTHER SALIENT FEATURES

2.17.1 It should be possible to check the healthiness of phase voltages by displaying all the voltageson the meter display.

2.17.2 The meter shall have provision of reading through communication port in the absence ofpower through a backup internal battery.


2.17.4 The meter should remain powered up and functional even when either of the two phases orone phase along with neutral is available to meter. 2.18 Sample Meter Three (3) nos. sample meterswith necessary fittings must be submitted with Techno Commercial Bid (Part- I). Sample meters shallbe tested at one of the utility or any test Lab by group of our technical experts as per specification.Date of testing shall be informed to all bidders. Engineer of the bidder shall have to be presentduring testing and well prepared & equipped to give satisfactory reply to all quaries.

3.0 Three Phase, Four Wire, 0.5 Class, Energy Meter for 3-Phase DT

3.1 CT REQUIREMENT

The Meter shall be supplied with four nos of C.T’s with primary current capacity as required for itsintended use. The Accuracy class of C.T shall be 0.5.The meter shall be suitable for use with ring type/Coil type

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[Epoxy/resin casted polyster] C.T whose Secondary current shall be 5 Amps. The C.T shall be woundprimary type.

3.2 DISPLAY

The Three phase meters shall be capable to measure & display continuously “Active Energy kWh” atall loads and power factors. The meter should have provision for automatic recording of cumulativekWh at 24 hrs on the last day of the month for each calendar month and same should go to memory.

The digitally measured and processed value shall be displayed through LCD/LED having minimum sixdigits to read upto one-tenth of kW hour with another digit for legend. The minimum characterheight shall not be less than 8 mm.

The Meter should have appropriate facilities to be read in absence of Power Supply.

3.3 AUTO SCROLL DISPLAY

i) Cumulative kWh ii) Instantaneous Voltages iii) Instantaneous Currents iv) Cummulative kVah v)Instantaneous pf phase-wise vi) Power on hours vii) Instantaneous load

3.4 DISPLAY PARAMETERS (PUSH BUTTON)

The display of following parameters shall be continuously scrolling one after another thru PushButton. The display shall have “ON“ time of 10 to 12 secs for each measured value for displaycycling.

i) Cumulative active Energy (kWh) for each calendar month for previous Six months. ii) Cumulativeapparent energy (kVah) for each calendar month for previous Six months iii) Maximum demand(MD) in apparent for last billing month iv) Maximum demand (MD) in apparent for current month v)Tamper Data : a) Present status of Tamper b) Date & time of last tamper occurrence & tamperidentification. c) Date & time of last tamper removal. d) Cumulative tamper occurrence count.

3.5 LOAD SURVEY CAPABILITY & BILLING POINT REQUIREMENTS

Following load survey parameters for 45 days shall be logged for 30 minute : x Individual phase wisekW value (one minute average) at peak kVA of 30 minute.

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x R, Y, B Individual voltage of phases x Power down time during 30 minute x Active forwardedenergy for 30 minute cumulative.

The predefined date and time for registering the billing parameters of kWh, kVAh, PF and kVA MD aswell as Tamper Count and Power-On hours readings shall be 00.00 hours of the first day of eachcalendar (billing) month. All billing parameters shall be transferred to billing registers and shall bedisplayed on auto cyclic display mode referred to as "BILLING PARAMETERS".

3.6 INTERFACE BETWEEN METER AND CMRI

The interface between a meter and CMRI shall be with a flexible cable of adequate length havingsuitable female connector. This cable shall be supplied along with meter. The two ends of the cableshall be stress relieved.

3.7 TAMPER &FRAUD PROTECTION

The meter registration shall be immune to reversal in current direction. The meter shall havefollowing anti- tamper features and shall record forward under the following conditions : a)Potential failure: The meter shall be capable of detecting and recording occurrences and restorationof potential failure (one phase/two phases) which can happen due to intentional / accidentaldisconnection of potential leads. The meter should also record event as a potential failure, whenone phase line fuse failure from the main side. b) Current Circuit Short: The meter shall be capableof detecting and recording occurrences and restoration of shorting of any one or two phases ofcurrent circuit. A event detection logic should be capable of discriminating the system abnormalitiesform source side and load side and it should not log /record event due to source side abnormalities.c) Current Circuit Open: The meter shall be capable of detecting and recording occurrences andrestoration of opening of any one or two phases of current circuit which can happen due tointentional / accidental disconnection of current circuits. No load condition should record in metermemory as a Current circuit open event. d) Current Unbalance: The meter shall be capable ofdetecting and recording occurrences and restoration of current unbalance as an event. The aboveinformation should be possible to download from the meter through hand held unit and available atBCS end. The current unbalance more than 30 % should be recorded as an event in the metermemory. e) Voltage Unbalance: The meter shall be capable of detecting and recording occurrencesand restoration of voltage unbalance as an event. The voltage unbalance more than 30 % should berecorded as an event in the meter memory. f) Performance of the meter should not get affectedfrom application of external AC/DC magnetic field. g) The meter should be immune to application of35kV spark discharge. h) The meter should be immune to application of high frequency jammer. i)Cover Open: The meter shall be able to detect cover open occurrence event if cover is opened inmains on or off condition. Separate legend for cover open event shall be made available on LCD. Thislegend shall remain in on state till meter reading so that it will come in to notice of meter reader.This tamper should be logged as non-rollover event.

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Minimum one hundred fifty (150) events (including occurrence & restoration) of all types ofabnormality event with date and time shall be available in the meter memory on first-in, first-outbasis. It shall be possible to retrieve the event data along-with all related snap- shots' data throughthe meter's optical port with the help of a hand held unit (HHU) and download the same to the BCSwhere it shall be available for viewing. All this information shall be available in simple and easilyunderstandable format.

3.8 NON INFLAMMABILITY

The terminal block, the terminal cover and the case shall ensure reasonable safety against spread offire. They shall not be ignited by thermic over load of live parts in contact with them. To comply withthis these parts shall fulfill the conditions of the glow wire test as per clause 5.2.4 of CBIP TechnicalReport No.88.

3.9 CONSTRUCTIONAL REQUIREMENTS

Meters shall be designed and constructed in such a way so as to avoid causing any danger duringuse and under normal conditions. The following should be ensured :

i.Personal safety against electric shock.

ii.Protection against spread of fire.

iii.Protection against effects of excessive temperature.

iv.Protection against penetration of solid objects, dust & water.

v.Protection against fraudulence.

vi.Protection against pilferage.

vii.Meter base and meter cover should be ultrasonically welded.

viii.Protection against meter jamming by spurious signal injection/high magnetic field application.

The meter shall be designed with application of specific integrated circuit.

3.10 METER CASE

The meter should be housed in a safe, high grade engineering polycarbonate meter casing ofprojection mounting type and is dust, vermin and moisture proof, with enclosure having degree ofprotection conforming to IP-51 as per IS 13947. The meter case shall seal the meter such that theinternal parts of meter are accessible only after breaking the seals of meter cover. The meter caseshall have provision with deep cut for hanging the meter.

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All insulating material used in the construction of meters shall be non-hygroscopic, non-ageing andof tested quality. All parts that are likely to develop corrosion shall be effectively protected againstsuch corrosion during operating life by providing suitable protective coating.

3.11 COVER

The cover shall be transparent, made of scratch resistant UV stabilized silicon coated polycarbonatematerial, which would enable easy reading the display. It should not fade in course of time andbecome opaque causing inconvenience for reading.

The cover shall permit clear view of the register.

3.12 TERMINAL AND TERMINAL BLOCK

The meter shall have extended terminal blocks and be supplied with transparent non-detachableextended terminal block cover (ETBC).

The combined meter block and ETBC shall ensure safety against the spread of fire. They should notbe ignited by overload of live parts in contact with them. To comply with this, these parts shall fulfillthe conditions of the glow wire test as per Clause 5.2.4 of CBIP Technical Report no 88.

The Extended terminal block cover (ETBC) shall be transparent and shall be fixed to the meterterminal block by at least one screw. The terminal block cover shall be provided with minimum oneseal.

The Combined meter terminal block and terminal block cover shall be moulded type and made ofhigh grade non-hygroscopic, fire retardant, low tracking, reinforced poly-carbonate (not bakelite) orequivalent high grade engineering plastic which should form an extension of the meter case andhave terminal holes and shall be of sufficient size to accommodate the insulation of the conductors.The terminals shall be of suitable rating to carry 150% of Imax and made of electro-plated (or tinnedbrass. Terminals shall be of adequate size so as to ensure proper tightening of the cable and shall beof replaceable type.

The terminal block shall have provision with two screws for fixing to a meter board.

3.13 TERMINATION

The terminals shall have suitable construction with barriers to provide firm and safe connection ofcurrent and voltage leads of stranded copper conductors or copper reducer type terminal ends(thimbles). Appropriate bi metallic lugs should be provided with each meter for fixing of theconductor.

46

The manner of fixing the conductors to the terminal block shall ensure adequate and durablecontact such that there is no risk of loosening or undue heating. Screw connections shall be suchthat the risk of corrosion resulting from contact with any other metal part is minimized. Electricalconnections shall be so designed that contact pressure is not transmitted through insulatingmaterial. The internal diameter of the terminal holes shall be 5.5 mm minimum. The clearance andcreepage distance shall conform to relevant clause of IS 14697:1999/CBIP technical report No. 88.

The meter shall have a design life of 10 years against manufacturing and design defects. TheManufacturer shall stand 1 years Guarantee on the meter against any kind of failure/defects/mal-operation within above period. Meter shall be replaced by manufacturer free of cost within onemonth of intimation by owner / Employer. Manufacturer shall have to repair for further 5 years afterthe guarantee period is over, on chargeable basis.

3.14 CONNECTION DIAGRAM

Each meter shall be indelibly marked with a connection diagram which shall be attached to the innerside of the extended terminal block cover. In case any special precautions need to be taken at thetime of testing the meter, the same may be indicated along with circuit diagram. The meterterminals shall also be marked and this marking should appear in the above diagram.

3.15 TERMINAL ARRANGEMENT

Three phase: The terminal arrangement and connection diagram shall be marked in accordancewith clause 7.2 of IS 14697.Terminal arrangement shall be in sequence : Ir(in), Vr, Ir(out), Iy(in), Vy,Iy(out), Ib(in), Vb, Ib (out), Neutral (in),Neutral(out), Vn.


Reliable sealing arrangement should be provided to make the meter tamper evidence and avoidfiddling or tampering by unauthorized persons by way of providing adequate no. of seals on meter,meter terminal cover, wherever necessary. All the seals shall be provided in front side only. Rear sidesealing arrangement will not be acceptable.

The manufacturer shall provide minimum two seals for the meter at the factory after calibration andtesting. The meter cover shall have provision for placing minimum two nos. additional seals by theEmployer. The manual switch and the terminal block cover shall be provided with minimum one sealeach.

The holes for sealing wire shall be minimum 2 mm dia.

All the sealing screws when they are in open condition (i.e. not fixed) should not be easilydetachable from the respective covers. The meter should be designed and constructed in such amanner to make it pilfer proof.

47

The meter cover and base should be ultrasonically/chemically welded on three sides of the meter sothat if the meter cover is opened there is clear evidence of tampering and the meter gets completelydamaged

3.17 ELECTRO-MAGNETIC COMPATIBILITY AND INTERFERENCE

The meter shall remain un-influenced with EMI/EMC interference. The meter shall withstand surgetest of 6 kV as per IS 14697-1999. It shall also withstand power frequency high voltage test of 2 kVrms for one minute.

3.18 TESTS

3.18.1 Routine & Acceptance Tests : All routine & acceptance tests shall be carried out on eachindividual meter. as stipulated in IS 14697 / CBIP Technical Report No. 88.

3.18.2 Type Tests The offered Energy Meters shall be fully type tested as per IS 14697 at any of theNABL accredited test laboratories and shall provide test certificate not more than 2 years old. AlsoDLMS test certificate as per IS 15959 at any NABL laboratory must be provided.


3.19 The communication port of the meter will be brought out a Box to a suitable height (~ 1.5 mabove GL) for taking the meter reading through CMRI. The Box shall have suitable lockingarrangement. 3.20 Sample Meter

Three (3) nos. sample meters with necessary fittings must be submitted with Techno Commercial Bid(Part- I). Sample meters shall be tested at one of the utility or any test Lab by group of our technicalexperts as per specification. Date of testing shall be informed to all bidders. Engineer of the biddershall have to be present during testing and well prepared & equipped to give satisfactory reply to allquaries.

4.0 SINGLE PHASE, TWO WIRE, ACCURACY CLASS 0.5, ENERGY METER FOR SINGLE PHASE DT

4.1 CT EQUIREMENT

The Meter shall be supplied with C.T with primary current capacity required for its intended use. TheAccuracy class of C.T shall be 0.5.The meter shall be suitable for use with ring type /Coil type C.Twhose Secondary current shall be 5 Amps. The C.T shall be wound primary type. Two nos. CT shall besupplied with each meter for Phase and Neutral circuit.

48

4.2 DISPLAY

The Single phase meters shall be capable to measure & display continuously “Active Energy kWh” atall loads and power-factors. The meter should have provision for automatic recording of cumulativekWh at 24 hrs on the last day of the month for each calendar month and same should go to memory.




i) Cumulative kWh ii) Instantaneous Voltages iii) Instantaneous Currents iv) Cummulative kVah v)Instantaneous pf vi) Power on hours vii) Instantaneous load


The display of following parameters shall be continuously scrolling one after another thru PushButton. The display shall have “ON “time of 10 secs for each measured value for display cycling.

i) Cumulative active Energy (kWh) for each calendar month for previous Six months. ii) Cumulativeapparent energy (kVah) for each calendar month for previous Six months iii) Instantaneous voltages,currents iv) Maximum demand (MD) in apparent for last billing month v) Maximum demand (MD) inapparent for current month vi) Tamper Data : a. Present status of Tamper b. Date & time of lasttamper occurrence & tamper identification. c. Date & time of last tamper removal. d. Cumulativetamper occurrence count.


Following load survey parameters for 45 days for 30 minute shall be logged : x Average apparentdemand

49

x Voltage x Power down time during 30 minute x Active forwarded energy.





The meter shall be capable of recording correctly in following anti-tamper condition:

i. The meter shall be capable of recording energy correctly even if input and output terminals areinterchanged. Also the meter shall record correctly even if phase and neutral are interchanged. ii.The registration must occur whether input phase/neutral wires are connected properly or they areinterchanged at the input terminals. iii. Performance of the meter should not be affected underinfluence of external DC/AC magnetic field of high intensity as mentioned in CBIP report 88. iv. Themeter shall withstand phase-to-phase voltage between phase and neutral terminals for at least 15minutes. v. The Meter shall record even when the Neutral is removed or opened from both ends(source & load) and when phase and Neutral are interchanged. When neutral is removed metershould start recording energy for current of 1 (one) amp and above. The accuracy of the metershould remain within +3% in this condition and the test should be completed within 10 minutes. vi.The meter should be immune to application of 35kV spark discharge. vii. The meter should beimmune to high frequency jammer. viii. Cover Open: The meter shall be able to detect cover openoccurrence event if cover is opened in mains on or off condition. Separate legend for cover openevent shall be made available on LCD. This legend shall remain in on state till meter reading so that itwill come in to notice of meter reader. This tamper should be logged as non-rollover event.


50

4.8 SELF DIAGONISTIC FEATURES

The contractor shall provide details of self-diagnostics features available and indication on the threephase meter for unsatisfactory / non-functioning of the following:

i) Time and calendar ii) Real time clock battery iii) All display segments iv) Non volatile memory





i. Personal safety against electric shock ii. Protection against spread of fire iii. Protection againstpenetration of solid objects, dust & water iv. Protection against fraudulence v. Protection againstpilferage vi. Meter base and meter cover should be ultrasonically welded vii. Protection againstmeter jamming by spurious signal injection/high magnetic field application.


4.10.2 Meter Case :



51

4.10.3 COVER:







The Combined meter terminal block and terminal block cover shall be moulded type and made ofhigh grade non-hygroscopic, fire retardant, low tracking, reinforced poly-carbonate (not bakelite) orequivalent high grade engineering plastic which should form an extension of the meter case andhave terminal holes and shall be of sufficient size to accommodate the insulation of the conductors.

The terminals shall be of suitable rating to carry 150% of Imax and made of electro-plated (or tinnedbrass. Terminals shall be of adequate size so as to ensure proper tightening of the cable and shall beof replaceable type.


4.12 TERMINATION


The manner of fixing the conductors to the terminal block shall ensure adequate and durablecontact such that there is no risk of loosening or undue heating. Screw connections shall be suchthat the risk of corrosion resulting from contact with any other metal part is minimized. Electricalconnections shall be so

52

designed that contact pressure is not transmitted through insulating material. The internal diameterof the terminal holes shall be 5.5 mm minimum. The clearance and creepage distance shall conformto relevant clause of IS 14697:1999/CBIP technical report No. 88.




Single phase: Connecting terminals of current and voltage shall be in following sequence: Phase (in),Neutral (in), Neutral (out), phase (out).



The manufacturer shall provide minimum two seals for the meter at the factory after calibration andtesting. The meter cover shall have provision for placing minimum two nos. additional seals by theEmployer. The Terminal block cover shall be provided with minimum one seal each.

The holes for sealing wire shall be minimum 2 mm diameter.


The meter cover and base should be ultrasonically/chemically welded on three sides so that if themeter cover is opened there is clear evidence of tampering and the meter gets completely damaged.


The meter shall remain un-influenced with EMI/EMC interference. The meter shall withstand surgetest of 6 kV as per IS 14697-1999. It shall also withstand power frequency high voltage test as perabove IS.

53

4.17 TESTS

4.17.1 Routine & Acceptance Tests: All routine tests shall be carried out on each individual meterand acceptance tests as stipulated in IS: 14697 / CBIP Technical Report No. 88.

4.17.2 Type Tests

Offered Energy Meters shall be fully type tested as per IS 14697 at any of the NABL accredited testlaboratories and shall provide test certificate not more than 2 years old. Also DLMS test certificate asper IS 15959 done at any NABL laboratory must be provided.




Three Phase, Four Wire, 0.5 Class, Energy Meter for 3-Phase DT

3.1 CT REQUIREMENT

The Meter shall be supplied with four nos of C.T’s with primary current capacity as required for itsintended use. The Accuracy class of C.T shall be 0.5.The meter shall be suitable for use with ring type/Coil type

42

[Epoxy/resin casted polyster] C.T whose Secondary current shall be 5 Amps. The C.T shall be woundprimary type.

3.2 DISPLAY

The Three phase meters shall be capable to measure & display continuously “Active Energy kWh” atall loads and power factors. The meter should have provision for automatic recording of cumulativekWh at 24 hrs on the last day of the month for each calendar month and same should go to memory.




i) Cumulative kWh ii) Instantaneous Voltages iii) Instantaneous Currents iv) Cummulative kVah v)Instantaneous pf phase-wise vi) Power on hours vii) Instantaneous load


The display of following parameters shall be continuously scrolling one after another thru PushButton. The display shall have “ON“ time of 10 to 12 secs for each measured value for displaycycling.

i) Cumulative active Energy (kWh) for each calendar month for previous Six months. ii) Cumulativeapparent energy (kVah) for each calendar month for previous Six months iii) Maximum demand(MD) in apparent for last billing month iv) Maximum demand (MD) in apparent for current month v)Tamper Data : a) Present status of Tamper b) Date & time of last tamper occurrence & tamperidentification. c) Date & time of last tamper removal. d) Cumulative tamper occurrence count.


Following load survey parameters for 45 days shall be logged for 30 minute : x Individual phase wisekW value (one minute average) at peak kVA of 30 minute.

43

x R, Y, B Individual voltage of phases x Power down time during 30 minute x Active forwardedenergy for 30 minute cumulative.




3.7 TAMPER &FRAUD PROTECTION

The meter registration shall be immune to reversal in current direction. The meter shall havefollowing anti- tamper features and shall record forward under the following conditions : a)Potential failure: The meter shall be capable of detecting and recording occurrences and restorationof potential failure (one phase/two phases) which can happen due to intentional / accidentaldisconnection of potential leads. The meter should also record event as a potential failure, whenone phase line fuse failure from the main side. b) Current Circuit Short: The meter shall be capableof detecting and recording occurrences and restoration of shorting of any one or two phases ofcurrent circuit. A event detection logic should be capable of discriminating the system abnormalitiesform source side and load side and it should not log /record event due to source side abnormalities.c) Current Circuit Open: The meter shall be capable of detecting and recording occurrences andrestoration of opening of any one or two phases of current circuit which can happen due tointentional / accidental disconnection of current circuits. No load condition should record in metermemory as a Current circuit open event. d) Current Unbalance: The meter shall be capable ofdetecting and recording occurrences and restoration of current unbalance as an event. The aboveinformation should be possible to download from the meter through hand held unit and available atBCS end. The current unbalance more than 30 % should be recorded as an event in the metermemory. e) Voltage Unbalance: The meter shall be capable of detecting and recording occurrencesand restoration of voltage unbalance as an event. The voltage unbalance more than 30 % should berecorded as an event in the meter memory. f) Performance of the meter should not get affectedfrom application of external AC/DC magnetic field. g) The meter should be immune to application of35kV spark discharge. h) The meter should be immune to application of high frequency jammer. i)Cover Open: The meter shall be able to detect cover open occurrence event if cover is opened inmains on or off condition. Separate legend for cover open event shall be made available on LCD. Thislegend shall remain in on state till meter reading so that it will come in to notice of meter reader.This tamper should be logged as non-rollover event.

44





Meters shall be designed and constructed in such a way so as to avoid causing any danger duringuse and under normal conditions. The following should be ensured :

i.Personal safety against electric shock.

ii.Protection against spread of fire.

iii.Protection against effects of excessive temperature.

iv.Protection against penetration of solid objects, dust & water.

v.Protection against fraudulence.

vi.Protection against pilferage.

vii.Meter base and meter cover should be ultrasonically welded.

viii.Protection against meter jamming by spurious signal injection/high magnetic field application.


3.10 METER CASE


45


3.11 COVER







The Combined meter terminal block and terminal block cover shall be moulded type and made ofhigh grade non-hygroscopic, fire retardant, low tracking, reinforced poly-carbonate (not bakelite) orequivalent high grade engineering plastic which should form an extension of the meter case andhave terminal holes and shall be of sufficient size to accommodate the insulation of the conductors.The terminals shall be of suitable rating to carry 150% of Imax and made of electro-plated (or tinnedbrass. Terminals shall be of adequate size so as to ensure proper tightening of the cable and shall beof replaceable type.


3.13 TERMINATION


46

The manner of fixing the conductors to the terminal block shall ensure adequate and durablecontact such that there is no risk of loosening or undue heating. Screw connections shall be suchthat the risk of corrosion resulting from contact with any other metal part is minimized. Electricalconnections shall be so designed that contact pressure is not transmitted through insulatingmaterial. The internal diameter of the terminal holes shall be 5.5 mm minimum. The clearance andcreepage distance shall conform to relevant clause of IS 14697:1999/CBIP technical report No. 88.

The meter shall have a design life of 10 years against manufacturing and design defects. TheManufacturer shall stand 1 years Guarantee on the meter against any kind of failure/defects/mal-operation within above period. Meter shall be replaced by manufacturer free of cost within onemonth of intimation by owner / Employer. Manufacturer shall have to repair for further 5 years afterthe guarantee period is over, on chargeable basis.


Each meter shall be indelibly marked with a connection diagram which shall be attached to the innerside of the extended terminal block cover. In case any special precautions need to be taken at the

time of testing the meter, the same may be indicated along with circuit diagram. The meterterminals shall also be marked and this marking should appear in the above diagram.


Three phase: The terminal arrangement and connection diagram shall be marked in accordancewith clause 7.2 of IS 14697.Terminal arrangement shall be in sequence : Ir(in), Vr, Ir(out), Iy(in), Vy,Iy(out), Ib(in), Vb, Ib (out), Neutral (in),Neutral(out), Vn.



The manufacturer shall provide minimum two seals for the meter at the factory after calibration andtesting. The meter cover shall have provision for placing minimum two nos. additional seals by theEmployer. The manual switch and the terminal block cover shall be provided with minimum one sealeach.

The holes for sealing wire shall be minimum 2 mm dia.


47

The meter cover and base should be ultrasonically/chemically welded on three sides of the meter sothat if the meter cover is opened there is clear evidence of tampering and the meter gets completelydamaged


The meter shall remain un-influenced with EMI/EMC interference. The meter shall withstand surgetest of 6 kV as per IS 14697-1999. It shall also withstand power frequency high voltage test of 2 kVrms for one minute.

3.18 TESTS

3.18.1 Routine & Acceptance Tests : All routine & acceptance tests shall be carried out on eachindividual meter. as stipulated in IS 14697 / CBIP Technical Report No. 88.

3.18.2 Type Tests The offered Energy Meters shall be fully type tested as per IS 14697 at any of theNABL accredited test laboratories and shall provide test certificate not more than 2 years old. AlsoDLMS test certificate as per IS 15959 at any NABL laboratory must be provided.




4.0 SINGLE PHASE, TWO WIRE, ACCURACY CLASS 0.5, ENERGY METER FOR SINGLE PHASEDT

4.1 CT EQUIREMENT

The Meter shall be supplied with C.T with primary current capacity required for its intended use. TheAccuracy class of C.T shall be 0.5.The meter shall be suitable for use with ring type /Coil type C.Twhose Secondary current shall be 5 Amps. The C.T shall be wound primary type. Two nos. CT shall besupplied with each meter for Phase and Neutral circuit.

48

4.2 DISPLAY

The Single phase meters shall be capable to measure & display continuously “Active Energy kWh” atall loads and power-factors. The meter should have provision for automatic recording of cumulativekWh at 24 hrs on the last day of the month for each calendar month and same should go to memory.




i) Cumulative kWh ii) Instantaneous Voltages iii) Instantaneous Currents iv) Cummulative kVah v)Instantaneous pf vi) Power on hours vii) Instantaneous load


The display of following parameters shall be continuously scrolling one after another thru PushButton. The display shall have “ON “time of 10 secs for each measured value for display cycling.

i) Cumulative active Energy (kWh) for each calendar month for previous Six months. ii) Cumulativeapparent energy (kVah) for each calendar month for previous Six months iii) Instantaneous voltages,currents iv) Maximum demand (MD) in apparent for last billing month v) Maximum demand (MD) inapparent for current month vi) Tamper Data : a. Present status of Tamper b. Date & time of lasttamper occurrence & tamper identification. c. Date & time of last tamper removal. d. Cumulativetamper occurrence count.


Following load survey parameters for 45 days for 30 minute shall be logged : x Average apparentdemand

49

x Voltage x Power down time during 30 minute x Active forwarded energy.





The meter shall be capable of recording correctly in following anti-tamper condition:

i. The meter shall be capable of recording energy correctly even if input and output terminals areinterchanged. Also the meter shall record correctly even if phase and neutral are interchanged. ii.The registration must occur whether input phase/neutral wires are connected properly or they areinterchanged at the input terminals. iii. Performance of the meter should not be affected underinfluence of external DC/AC magnetic field of high intensity as mentioned in CBIP report 88. iv. Themeter shall withstand phase-to-phase voltage between phase and neutral terminals for at least 15minutes. v. The Meter shall record even when the Neutral is removed or opened from both ends(source & load) and when phase and Neutral are interchanged. When neutral is removed metershould start recording energy for current of 1 (one) amp and above. The accuracy of the metershould remain within +3% in this condition and the test should be completed within 10 minutes. vi.The meter should be immune to application of 35kV spark discharge. vii. The meter should beimmune to high frequency jammer. viii. Cover Open: The meter shall be able to detect cover openoccurrence event if cover is opened in mains on or off condition. Separate legend for cover openevent shall be made available on LCD. This legend shall remain in on state till meter reading so that itwill come in to notice of meter reader. This tamper should be logged as non-rollover event.


50

4.8 SELF DIAGONISTIC FEATURES

The contractor shall provide details of self-diagnostics features available and indication on the threephase meter for unsatisfactory / non-functioning of the following:

i) Time and calendar ii) Real time clock battery iii) All display segments iv) Non volatile memory





i. Personal safety against electric shock ii. Protection against spread of fire iii. Protection againstpenetration of solid objects, dust & water iv. Protection against fraudulence v. Protection againstpilferage vi. Meter base and meter cover should be ultrasonically welded vii. Protection againstmeter jamming by spurious signal injection/high magnetic field application.


4.10.2 Meter Case :



51

4.10.3 COVER:







The Combined meter terminal block and terminal block cover shall be moulded type and made ofhigh grade non-hygroscopic, fire retardant, low tracking, reinforced poly-carbonate (not bakelite) orequivalent high grade engineering plastic which should form an extension of the meter case andhave terminal holes and shall be of sufficient size to accommodate the insulation of the conductors.

The terminals shall be of suitable rating to carry 150% of Imax and made of electro-plated (or tinnedbrass. Terminals shall be of adequate size so as to ensure proper tightening of the cable and shall beof replaceable type.


4.12 TERMINATION


The manner of fixing the conductors to the terminal block shall ensure adequate and durablecontact such that there is no risk of loosening or undue heating. Screw connections shall be suchthat the risk of corrosion resulting from contact with any other metal part is minimized. Electricalconnections shall be so

52

designed that contact pressure is not transmitted through insulating material. The internal diameterof the terminal holes shall be 5.5 mm minimum. The clearance and creepage distance shall conformto relevant clause of IS 14697:1999/CBIP technical report No. 88.




Single phase: Connecting terminals of current and voltage shall be in following sequence: Phase (in),Neutral (in), Neutral (out), phase (out).



The manufacturer shall provide minimum two seals for the meter at the factory after calibration andtesting. The meter cover shall have provision for placing minimum two nos. additional seals by theEmployer. The Terminal block cover shall be provided with minimum one seal each.

The holes for sealing wire shall be minimum 2 mm diameter.


The meter cover and base should be ultrasonically/chemically welded on three sides so that if themeter cover is opened there is clear evidence of tampering and the meter gets completely damaged.


The meter shall remain un-influenced with EMI/EMC interference. The meter shall withstand surgetest of 6 kV as per IS 14697-1999. It shall also withstand power frequency high voltage test as perabove IS.

53

4.17 TESTS

4.17.1 Routine & Acceptance Tests: All routine tests shall be carried out on each individual meterand acceptance tests as stipulated in IS: 14697 / CBIP Technical Report No. 88.

4.17.2 Type Tests

Offered Energy Meters shall be fully type tested as per IS 14697 at any of the NABL accredited testlaboratories and shall provide test certificate not more than 2 years old. Also DLMS test certificate asper IS 15959 done at any NABL laboratory must be provided.



TENDER DRAWINGS

VOLUME-III : SECTION – II

M.S COUPLE PIN

S.S SPLIT PIN

SILICONE RUBBER HOUSING

12

H

G

F

E

D

C

B

12

A

46

57

3

346 57891011

89101112

H

G

F

E

D

C

B

A

12

REV. NO.

R0

PREPAREDBY

CHECKEDBY

APPROVEDBY

DATEPROJECT 01 OF 1

FOR TENDER PURPOSE ONLY

Rural Electrification Corporation Ltd.

11 KV 45KN COMPOSITE INSULATOR

O 16

O91+1

Deen Dayal Upadhyaya Gram Jyoti Yojana( DDUGJY)

REC/DDUGJY/11kV/08

Equivalent of Voltsin Local Language

Equivalent of Danger inLocal Language

4) MANUFACTURING TOLERANCE AS FOLLOWS

NOTES:-1) THE PLATE SHALL BE MADE FROM M.S. SHEET OF ATLEAST 1.6mm THICKNESS

& VITREOUS ENAMELED WHITE WITH LETTERS, FIGURES & THE CONVENTIONAL SKULL& BONES IN SIGNAL RED COLOUR ON THE FRONT SIDE(IS 5-1978). THE REAR SIDEOF THE PLATE SHALL ALSO BE ENAMELED.

2) ALL LETTERING SHOULD BE CENTRALLY SPACED.

3) ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE MENTIONED.

UP TO 50mm51 TO 100mm101 TO 300mmABOVE 300mm

••• • • • • • • •••• • • • • • • •••• • • • • • • •••• • • • • • • •

• • • • • •• • • • • • • • • • • • • • • •

• • • • • •• • • • • • • • • • • • • • • •

12

H

G

F

E

D

C

B

12

A

46 57 3

1011

891011 12

H

G

F

E

D

C

B

A

All dimensions are in mm.

REV. NO.

R0

PREPAREDBY

CHECKEDBY

APPROVEDBY

DATEPROJECT 01 OF 1



NOTES:- All markings are obtained during moudling itself.-Markings:Raychem,Type, Ur (Rating),Us (cov),In (Non discharge current), Isc(short circuit capability),Mfg month & year

LOT No DATE CLOCKS

Meter Board


REC/DDUGJY/DTR-SS/13A

Lay Out Drawing of Lighting Arrestor (1)

12

H

G

F

E

D

C

B

12

A

46 57 3

1011

891011 12

H

G

F

E

D

C

B

A

All dimensions are in mm.REV. NO.

R0

PREPAREDBY

CHECKEDBY

APPROVEDBY

DATEPROJECT 01 OF 1



NOTES:-Nominal COV Uc = 8kVNominal rating Uc =10 kVNominal discharge current -5kANominal creepage distance = 330mmNominal dry arcing distance=163mm

MV SURGE ARRESTERTYPE:NDA WITH DISCONNECTOR

MV SURGE ARRESTERTYPE:NDAHOUSING DETAILS

MATERIAL :POLMER-EVA

M-10

M-10

cable withlug

cable withlug

128+5

105+5

146+5

R 3.00

R 1.50


REC/DDUGJY/DTR-SS/13B


12

H

G

F

E

D

C

B

12

A

46 57 3

1011

891011 12

H

G

F

E

D

C

B

A

All dimensions are in mm.

REV. NO.

R0

PREPAREDBY

CHECKEDBY

APPROVEDBY

DATEPROJECT 01 OF 1



NOTES:-Nominal COV Uc = 8kVNominal rating Uc =10 kVNominal discharge current -5kANominal creepage distance = 330mmNominal dry arcing distance=163mm

MV SURGE ARRESTERTYPE:NDASECTIONAL VIEW

SECTION A-A

M-10 A A


REC/DDUGJY/DTR-SS/13C


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